New 6xxx aluminum alloy

Abstract

New 6xxx aluminum alloy products are disclosed that may contain tin and may achieve improved combinations of properties, such as improved combinations of two or more of strength, ductility (elongation), extrudability, extrusion temperature, extrusion rate, and absence of visually apparent surface defects.

Description

[Background technology]

[0001] The 6xxx aluminum alloys are aluminum alloys containing silicon and magnesium that produce the magnesium silicide (MgSi) phase. Alloy 6061 has been used in a variety of applications for several decades. However, it has not been clear how to improve one or more properties of the aluminum alloy without degrading others.

[0002] Free-cutting 6xxx aluminum alloys (including those containing tin) are described in commonly owned US Pat. Nos. 5,522,950 and 7,422,645. Summary of the Invention

[0003] Generally, this patent application relates to novel 6xxx aluminum alloys and methods for making the same. The new 6xxx aluminum alloys generally contain 0.5-1.5 wt.% Sn, 0.4-1.6 wt.% Si, 0.6-1.2 wt.% Mg (wherein the weight ratio of (wt.% Si) to (wt.% Mg) is at least 0.75:1), 0.5-1.1 wt.% Cu, 0.15-1.5 wt.% Mn, 0.10-0.80 wt.% Fe (wherein (wt.% Si) + (wt.% Mn) + (wt.% Fe) is at least 0.95 wt.%), maximum 1.2 wt.% Bi, maximum 1.2 wt.% In, maximum 1.0 wt.% Zn, maximum 0.35 wt.% Cr, maximum 0.25 wt.% V, maximum 0.25 wt.% Zr, maximum 0.15 wt.% Ti, and maximum 0.04 wt.% Pb, with the balance being aluminum, optional incidental elements, and impurities. In one embodiment, the new 6xxx aluminum alloys are in the form of extruded products.

[0004] Products made from the new 6xxx aluminum alloys may achieve improved combinations of properties, such as improved combinations of two or more of strength, ductility (elongation), extrudability, extrusion temperature, extrusion rate, and absence of visually apparent surface defects (e.g., absence of cracks, hot tears, etc.). The new aluminum alloys can be used in a variety of applications, including lead (Pb) free-machining applications.

[0005] In one embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.30%, where the dispersoids comprise at least FeMnSi dispersoids. A high volume fraction of dispersoids can facilitate the production of improved products having, among other things, high strength, ductility, extrudability, lower extrusion temperatures, and / or higher extrusion speeds, for example, without substantially sacrificing machinability.

[0006] i.Composition As discussed above, the new 6xxx aluminum alloys generally contain 0.5-1.5 wt.% Sn, 0.4-1.6 wt.% Si, 0.6-1.2 wt.% Mg (wherein the weight ratio of (wt.% Si) to (wt.% Mg) is at least 0.75:1), 0.5-1.1 wt.% Cu, 0.15-1.5 wt.% Mn, 0.10-0.80 wt.% Fe (wherein the weight ratio of (wt.% Si) + (wt.% Mn) + (wt.% % Ti, and max. 0.04 wt. % Pb, the balance being aluminum, any incidental elements, and impurities.

[0007] As noted above, the new 6xxx aluminum alloys generally contain 0.5-1.5 wt.% Sn. Tin may, among other things, promote the machinability of the new 6xxx aluminum alloy products. In one embodiment, the new 6xxx aluminum alloy products contain at least 0.55 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.60 wt.% Sn. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.65 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.70 wt.% Sn. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.75 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.80 wt.% Sn. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.85 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.90 wt.% Sn. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 0.95 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy product contains at least 1.0 wt.% Sn. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 1.05 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy product contains at least 1.10 wt.% Sn.

[0008] In one embodiment, the new 6xxx aluminum alloy products contain up to 1.45 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy products contain up to 1.40 wt.% Sn. In yet another embodiment, the new 6xxx aluminum alloy products contain up to 1.35 wt.% Sn. In another embodiment, the new 6xxx aluminum alloy products contain up to 1.30 wt.% Sn.

[0009] As noted above, the new 6xxx aluminum alloys generally contain 0.4-1.6 wt.% Si. Silicon in combination with magnesium may, among other things, promote the presence of the Mg2Si phase. Increasing silicon levels may also facilitate the production of higher volume fractions of FeMn3Si2 dispersoids without substantially affecting the volume fraction of the Mg2Si phase present in the alloy. In one embodiment, the new 6xxx aluminum alloy products contain at least 0.45 wt.% Si. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.50 wt.% Si. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.55 wt.% Si. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.60 wt.% Si. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.65 wt.% Si. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.70 wt.% Si. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.75 wt.% Si. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.80 wt.% Si.

[0010] In one embodiment, the new 6xxx aluminum alloy product contains 1.55 wt.% Si or less. In another embodiment, the new 6xxx aluminum alloy product contains 1.50 wt.% Si or less. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.45 wt.% Si or less. In another embodiment, the new 6xxx aluminum alloy product contains 1.40 wt.% Si or less. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.35 wt.% Si or less. In another embodiment, the new 6xxx aluminum alloy product contains 1.30 wt.% Si or less. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.25 wt.% Si or less. In another embodiment, the new 6xxx aluminum alloy product contains 1.20 wt.% Si or less. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.15 wt.% Si or less. In another embodiment, the new 6xxx aluminum alloy product contains 1.10 wt.% Si or less. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.05 wt.% Si or less. In another embodiment, the new 6xxx aluminum alloy products contain up to 1.0 wt.% Si. In yet another embodiment, the new 6xxx aluminum alloy products contain up to 0.95 wt.% Si. In another embodiment, the new 6xxx aluminum alloy products contain up to 0.90 wt.% Si.

[0011] As noted above, the new 6xxx aluminum alloys generally contain 0.6-1.2 wt.% Mg (e.g., to achieve an appropriate volume fraction of the MgSi phase and / or work hardening effect). In one embodiment, the new 6xxx aluminum alloy products contain at least 0.65 wt.% Mg. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.70 wt.% Mg.

[0012] In one embodiment, the new 6xxx aluminum alloy product contains up to 1.15% Mg by weight. In another embodiment, the new 6xxx aluminum alloy product contains up to 1.10% Mg by weight. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 1.05% Mg by weight. In another embodiment, the new 6xxx aluminum alloy product contains up to 1.0% Mg by weight. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.95% Mg by weight. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.90% Mg by weight. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.85% Mg by weight.

[0013] In one embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy product is at least 0.80:1 ((wt % Si) to (wt % Mg)). In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy product is at least 0.85:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy product is at least 0.90:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy product is at least 0.95:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy product is at least 1.0:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy product is at least 1.05:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is at least 1.10: 1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is at least 1.15: 1.

[0014] In one embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 2.2:1 or less. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 2.1:1 or less. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 2.0:1 or less. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.9:1 or less. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.8:1 or less. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.7:1 or less. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.6:1 or less. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.5:1 or less. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.4:1 or less. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.3:1 or less. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the new 6xxx aluminum alloy products is 1.2:1 or less.

[0015] In one embodiment, the total amount of silicon and magnesium (weight percent) in the new 6xxx aluminum alloy product is at least 1.3 wt.% (i.e., (wt.% Si) + (wt.% Mg) > 1.3 wt.%). In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.35 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.40 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.45 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.50 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.55 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.60 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.65 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is at least 1.70 wt.%.

[0016] In one embodiment, the total amount of silicon and magnesium (weight percent) in the new 6xxx aluminum alloy product is less than or equal to 2.6 wt.% (i.e., (wt. %Si) + (wt. %Mg) < 2.6 wt.%). In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 2.5 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 2.4 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 2.3 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 2.2 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 2.1 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 2.0 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 1.9 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 1.85 wt.%. In yet another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 1.80 wt.%. In another embodiment, the total amount of silicon and magnesium in the new 6xxx aluminum alloy product is less than or equal to 1.75 wt.%.

[0017] As noted above, the new 6xxx aluminum alloys generally contain 0.5-1.1 wt.% Cu. Copper may promote the formation of strengthening phases, such as Q phase. In one embodiment, the new 6xxx aluminum alloy products contain at least 0.55 wt.% Cu. In another embodiment, the new 6xxx aluminum alloy products contain at least 0.60 wt.% Cu. In yet another embodiment, the new 6xxx aluminum alloy products contain at least 0.65 wt.% Cu.

[0018] In one embodiment, the new 6xxx aluminum alloy product contains up to 1.05 wt.% Cu. In another embodiment, the new 6xxx aluminum alloy product contains up to 1.0 wt.% Cu. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.95 wt.% Cu. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.90 wt.% Cu. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.85 wt.% Cu. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.80 wt.% Cu. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.75 wt.% Cu.

[0019] As noted above, the new 6xxx aluminum alloys generally contain 0.15-1.5 wt.% Mn. Manganese may, for example, promote the formation of a high volume fraction of FeMn3Si2 and other dispersoids. In one embodiment, the new 6xxx aluminum alloy product contains at least 0.18 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains at least 0.20 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 0.22 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains at least 0.24 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 0.26 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains at least 0.28 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 0.30 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains at least 0.32 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product includes at least 0.34 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product includes at least 0.36 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product includes at least 0.38 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product includes at least 0.40 wt.% Mn.

[0020] In one embodiment, the new 6xxx aluminum alloy product contains 1.45 wt.% or less Mn. In another embodiment, the new 6xxx aluminum alloy product contains 1.40 wt.% or less Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.35 wt.% or less Mn. In another embodiment, the new 6xxx aluminum alloy product contains 1.30 wt.% or less Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.25 wt.% or less Mn. In another embodiment, the new 6xxx aluminum alloy product contains 1.20 wt.% or less Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.15 wt.% or less Mn. In another embodiment, the new 6xxx aluminum alloy product contains 1.10 wt.% or less Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains 1.05 wt.% or less Mn. In another embodiment, the new 6xxx aluminum alloy product contains 1.0 wt.% or less Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains 0.95 wt.% or less Mn. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.90 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.85 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.80 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.75 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.70 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.65 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.60 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.55 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.50 wt.% Mn. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.45 wt.% Mn. In another embodiment, the new 6xxx aluminum alloy products include up to 0.42 wt. % Mn.

[0021] As noted above, the new 6xxx aluminum alloys generally include 0.10-0.80 wt.% Fe. Iron may, for example, promote the formation of a high volume fraction of FeMn3Si2 and other dispersoids. In one embodiment, the new 6xxx aluminum alloy products include at least 0.15 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy products include at least 0.20 wt.% Fe. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.25 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy products include at least 0.30 wt.% Fe. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.35 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy products include at least 0.40 wt.% Fe. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.45 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy products include at least 0.50 wt.% Fe.

[0022] In one embodiment, the new 6xxx aluminum alloy product contains up to 0.75 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.70 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.65 wt.% Fe. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.60 wt.% Fe. In another embodiment, the new 6xxx aluminum alloy product contains up to 0.55 wt.% Fe. In yet another embodiment, the new 6xxx aluminum alloy product contains up to 0.52 wt.% Fe.

[0023] As noted above, the new 6xxx aluminum alloys generally have a total weight percent of silicon, manganese, and iron of at least 0.95 wt.% (i.e., (wt. %Si) + (wt. %Mn) + (wt. %Fe) > 0.95 wt.%). In one embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.0 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.05 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.10 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.15 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.20 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.25 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.30 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.35 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.40 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.45 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.50 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.55 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is at least 1.60 wt.%.

[0024] In one embodiment, the total amount (weight percent) of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 3.1 wt.% or less (i.e., (wt.%Si) + (wt.%Mn) + (wt.%Fe) < 3.1 wt.%). In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 3.0 wt.% or less. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 2.9 wt.% or less. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 2.8 wt.% or less. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 2.7 wt.% or less. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 2.6 wt.% or less. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is 2.5 wt.% or less. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 2.4 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 2.3 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 2.2 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 2.1 wt.%. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 2.0 wt. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 1.9 wt. In another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 1.8 wt.%. In yet another embodiment, the total amount of silicon, manganese, and iron in the new 6xxx aluminum alloy product is equal to or less than 1.7 wt.%.

[0025] As noted above, the new 6xxx aluminum alloys may contain up to 1.2 wt.% Bi. Bismuth may substitute, in whole or in part, for tin in some alloying systems. However, the bismuth phase is generally less preferred than the tin phase. Thus, in some embodiments, the new 6xxx aluminum alloy products contain less than 0.25 wt.% Bi. In one embodiment, the new 6xxx aluminum alloy products contain 0.20 wt.% or less Bi. In another embodiment, the new 6xxx aluminum alloy products contain 0.15 wt.% or less Bi. In another embodiment, the new 6xxx aluminum alloy products contain 0.10 wt.% or less Bi. In yet another embodiment, the new 6xxx aluminum alloy products contain 0.08 wt.% or less Bi. In another embodiment, the new 6xxx aluminum alloy products contain 0.05 wt.% or less Bi. In yet another embodiment, the new 6xxx aluminum alloy products contain 0.03 wt.% or less Bi. In another embodiment, the new 6xxx aluminum alloy products contain 0.01 wt.% or less Bi. In yet another embodiment, the new 6xxx aluminum alloy products contain up to 0.005 wt.% Bi.

[0026] In embodiments in which bismuth is used, the new 6xxx aluminum alloy products generally contain 0.25-1.2 wt. % Bi.

[0027] As noted above, the new 6xxx aluminum alloys may contain up to 1.2 wt.% In. Indium may substitute, in whole or in part, for tin in some alloying systems. However, the indium phase is generally less preferred than the tin phase. Thus, in some embodiments, the new 6xxx aluminum alloy products contain less than 0.25 wt.% In. In one embodiment, the new 6xxx aluminum alloy products contain 0.20 wt.% or less In. In another embodiment, the new 6xxx aluminum alloy products contain 0.15 wt.% or less In. In another embodiment, the new 6xxx aluminum alloy products contain 0.10 wt.% or less In. In yet another embodiment, the new 6xxx aluminum alloy products contain 0.08 wt.% or less In. In another embodiment, the new 6xxx aluminum alloy products contain 0.05 wt.% or less In. In yet another embodiment, the new 6xxx aluminum alloy products contain 0.03 wt.% or less In. In another embodiment, the new 6xxx aluminum alloy products contain 0.01 wt.% or less In. In yet another embodiment, the new 6xxx aluminum alloy products contain up to 0.005 wt. % In.

[0028] In embodiments in which indium is used, the new 6xxx aluminum alloy products generally contain 0.25-1.2 wt. % In.

[0029] In one embodiment, the new 6xxx aluminum alloy product contains 0.5-1.5 wt.% Sn (e.g., at any of the tin levels recited herein), and the new 6xxx aluminum alloy product contains less than 0.05 wt.% Bi and less than 0.05 wt.% In. In another embodiment, the new 6xxx aluminum alloy product contains 0.5-1.5 wt.% Sn (e.g., at any of the tin levels recited herein), and the new 6xxx aluminum alloy product contains less than 0.03 wt.% Bi and less than 0.03 wt.% In. In yet another embodiment, the new 6xxx aluminum alloy product contains 0.5-1.5 wt.% Sn (e.g., at any of the tin levels recited herein), and the new 6xxx aluminum alloy product contains less than 0.01 wt.% Bi and less than 0.01 wt.% In.

[0030] In one embodiment, the new 6xxx aluminum alloy product includes at least two of tin, bismuth, and indium in an amount of at least 0.25 wt.% each. In another embodiment, the new 6xxx aluminum alloy product includes all of tin, bismuth, and indium in an amount of at least 0.25 wt.% each.

[0031] As noted above, the new 6xxx aluminum alloys may include up to 1.0 wt.% Zn. Zinc may facilitate solid solution strengthening. In one embodiment, the new 6xxx aluminum alloy products include at least 0.01 wt.% Zn. In one embodiment, the new 6xxx aluminum alloy products include not more than 0.9 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.8 wt.% Zn. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.7 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.6 wt.% Zn. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.50 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.40 wt.% Zn. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.30 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.20 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.15 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products contain up to 0.10 wt.% Zn. In yet another embodiment, the new 6xxx aluminum alloy products contain up to 0.08 wt.% Zn. In another embodiment, the new 6xxx aluminum alloy products contain up to 0.05 wt.% Zn. In yet another embodiment, the new 6xxx aluminum alloy products contain up to 0.03 wt.% Zn.

[0032] As noted above, the new 6xxx aluminum alloys may include up to 0.35 wt.% Cr. Chromium may, for example, promote the formation of chromium-containing dispersoids. In one embodiment, the new 6xxx aluminum alloy products include at least 0.01 wt.% Cr. In another embodiment, the new 6xxx aluminum alloy products include at least 0.03 wt.% Cr. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.06 wt.% Cr. In another embodiment, the new 6xxx aluminum alloy products include at least 0.08 wt.% Cr. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.10 wt.% Cr. In another embodiment, the new 6xxx aluminum alloy products include at least 0.12 wt.% Cr. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.14 wt.% Cr. In another embodiment, the new 6xxx aluminum alloy products include at least 0.16 wt.% Cr. In yet another embodiment, the new 6xxx aluminum alloy products include at least 0.18 wt.% Cr.

[0033] In one embodiment, the new 6xxx aluminum alloy products include up to 0.30 wt.% Cr. In another embodiment, the new 6xxx aluminum alloy products include up to 0.25 wt.% Cr. In yet another embodiment, the new 6xxx aluminum alloy products include up to 0.22 wt.% Cr. In another embodiment, the new 6xxx aluminum alloy products include up to 0.20 wt.% Cr.

[0034] As noted above, the new 6xxx aluminum alloys may include up to 0.25 wt.% V. Vanadium may be substituted, in whole or in part, for chromium. In one embodiment, the new 6xxx aluminum alloy products include at least 0.01 wt.% V. In one embodiment, the new 6xxx aluminum alloy products include not more than 0.15 wt.% V. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.10 wt.% V. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.08 wt.% V. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.05 wt.% V. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.03 wt.% V. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.01 wt.% V. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.005 wt.% V.

[0035] As noted above, the new 6xxx aluminum alloys may include up to 0.25 wt.% Zr. Zirconium may be substituted, in whole or in part, for chromium. In one embodiment, the new 6xxx aluminum alloy products include at least 0.01 wt.% Zr. In one embodiment, the new 6xxx aluminum alloy products include not more than 0.15 wt.% Zr. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.10 wt.% Zr. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.08 wt.% Zr. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.05 wt.% Zr. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.03 wt.% Zr. In another embodiment, the new 6xxx aluminum alloy products include not more than 0.01 wt.% Zr. In yet another embodiment, the new 6xxx aluminum alloy products include not more than 0.005 wt.% Zr.

[0036] In one embodiment, at least one of zirconium and vanadium partially substitutes for chromium.

[0037] As noted above, the new 6xxx aluminum alloys generally contain 0.15 wt.% or less Ti. Titanium may be used during casting for grain refinement. It is necessary to limit the amount of titanium in the alloy so that large primary particles are avoided / restricted / limited during production of the alloy product. In one embodiment, the new 6xxx aluminum alloy product contains at least 0.005 wt.% Ti. In another embodiment, the new 6xxx aluminum alloy product contains at least 0.01 wt.% Ti. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 0.02 wt.% Ti. In yet another embodiment, the new 6xxx aluminum alloy product contains at least 0.05 wt.% Ti. In one embodiment, the new 6xxx aluminum alloy product contains at most 0.12 wt.% Ti. In another embodiment, the new 6xxx aluminum alloy product contains at most 0.10 wt.% Ti. In another embodiment, the new 6xxx aluminum alloy product contains at most 0.08 wt.% Ti. In yet another embodiment, the new 6xxx aluminum alloy product contains at most 0.05 wt.% Ti. In another embodiment, the new 6xxx aluminum alloy products contain up to 0.03 wt.% Ti. In one embodiment, the new 6xxx aluminum alloy products contain 0.005-0.10 wt.% Ti. In another embodiment, the new 6xxx aluminum alloy products contain 0.01-0.05 wt.% Ti. In yet another embodiment, the new 6xxx aluminum alloy products contain 0.01-0.03 wt.% Ti. The titanium may be in elemental or compound form (e.g., TiB2 or TiC).

[0038] As noted above, the new 6xxx aluminum alloys generally contain 0.04 wt.% or less of Pb. Lead may be considered hazardous in some countries. In one embodiment, the new 6xxx aluminum alloys contain 0.03 wt.% or less of Pb. In another embodiment, the new 6xxx aluminum alloy products contain 0.01 wt.% or less of Pb. In yet another embodiment, the new 6xxx aluminum alloy products contain 0.005 wt.% or less of Pb.

[0039] As noted above, the balance of an aluminum alloy generally consists of aluminum, optional accessory elements, and impurities. As used herein, "accessory elements" refers to elements or materials, other than those listed above, that can be optionally added to an alloy to aid in the production of the alloy. Examples of accessory elements include casting aids such as grain refiners and deoxidizers. Optional accessory elements may be included in the alloy in a cumulative amount of up to 1.0 wt.%. As one non-limiting example, one or more accessory elements may be added to the alloy during casting to reduce or limit (and in some cases eliminate) cracking of the ingot due to, for example, oxide folds, pits, and oxide patches. These types of accessory elements are generally referred to herein as deoxidizers. Examples of some deoxidizers include Ca, Sr, and Be. When calcium (Ca) is included in the alloy, it is generally present in an amount of up to about 0.05 wt.%, or up to about 0.03 wt.%. In some embodiments, Ca is included in the alloy in an amount of about 0.001-0.03 wt. % or about 0.05 wt. %, such as 0.001-0.008 wt. % (or 10-80 ppm). Strontium (Sr) can be included in the alloy (in whole or in part) as a substitute for Ca, and thus can be included in the alloy in the same or similar amount as Ca. Traditionally, the addition of beryllium (Be) has helped reduce the tendency of ingots to crack, but for environmental, health, and safety reasons, some embodiments of the alloy are substantially free of Be. When Be is included in the alloy, it is generally present in an amount up to about 20 ppm. Accessory elements can be present in minor or significant amounts, and may themselves add desirable or other properties without departing from the alloy described herein, so long as the alloy retains the desired properties described herein. However, it should be understood that the scope of the present disclosure should not / cannot be circumvented by simply adding elements in amounts that would not otherwise affect the desired obtained property combination herein.

[0040] The new 6xxx aluminum alloys may contain small amounts of impurities. In one embodiment, the new 6xxx aluminum alloy products contain no more than 0.15 wt.% total impurities, and wherein the new aluminum alloy contains no more than 0.05 wt.% of each impurity. In another embodiment, the new 6xxx aluminum alloy products contain no more than 0.10 wt.% total impurities, and wherein the new aluminum alloy contains no more than 0.03 wt.% of each impurity.

[0041] ii. Processing The new aluminum alloy may be useful in various product forms, including, for example, ingots or billets, wrought product forms (plate, forgings, and extrusions), molded castings, additively manufactured products, and powder metallurgy products. For example, the new aluminum alloy may be processed into various wrought forms, such as, for example, rolled forms (sheet, plate), extrusions, or forgings, in various tempers. In this regard, the new aluminum alloy may be cast (e.g., direct chill or continuous casting) and then processed (hot and / or cold worked) into the appropriate product form (sheet, plate, extrusion, or forging). After processing, the new aluminum alloy may be processed to one of the T-, W-, O-, or F-tempers in accordance with ANSI H35.1 (2009). In one embodiment, the new aluminum alloy is processed (heat treated) to the "T-temper." In this regard, the new aluminum alloy can be processed to any of the T1, T2, T3, T4, T5, T6, T7, T8, T9, or T10 tempers in accordance with ANSI H35.1 (2009). In one embodiment, the product is processed to a T1 temper. In another embodiment, the product is processed to a T2 temper. In yet another embodiment, the product is processed to a T3 temper. In another embodiment, the product is processed to a T4 temper. In another embodiment, the product is processed to a T5 temper. In yet another embodiment, the product is processed to a T6 temper. In another embodiment, the product is processed to a T7 temper. In yet another embodiment, the product is processed to a T8 temper. In another embodiment, the product is processed to a T9 temper. In yet another embodiment, the product is processed to a T10 temper. In other embodiments, the new aluminum alloy is processed (solution heat treated) to the "W temper." In another embodiment, no solution heat treatment is applied after the aluminum alloy is processed into a suitable product form, and therefore the new aluminum alloy may be processed to an "F-temper" (as fabricated) or an "O-temper" (as annealed).

[0042] In one embodiment, the new 6xxx aluminum alloy product is an extruded product. In one embodiment, the extruded product is processed to a T1, T2, T3, T4, T5, T6, T7, T8, T9, or T10 temper. For example, the extruded product may be produced by producing a billet of any of the 6xxx aluminum alloys described herein, followed by scalping / peeling and homogenization (in any order), followed by extrusion (directly or indirectly) at the extrusion temperature. Any suitable extrusion technique, including isostatic extrusion, may be utilized. The extruded product may be in any suitable form, such as a rod, bar, shape, or any other geometric shape / profile. The extruded product may be an intermediate product or a final product. Immediately after extrusion, the product may be intentionally quenched and press-quenched to produce a naturally aged, i.e., T1 temper, and / or an artificially aged, i.e., T5 temper, product. Alternatively, the extruded product may be solution heat treated (e.g., in a separate furnace), quenched, and then naturally aged, i.e., a T4 temper product, and / or artificially aged, i.e., a T6 temper product. In another embodiment, the extruded product is further cold worked and / or artificially aged after extrusion. For a T8 temper, cold working is completed first, followed by artificial aging. For a T9 temper, artificial aging is completed first, followed by cold working.

[0043] Unlike the extrusion conditions described in commonly owned U.S. Patent No. 7,422,645, billets made from the new 6xxx aluminum alloy products described herein can be homogenized at any suitable homogenization temperature (e.g., 1010°F to 1040°F) and then (a) immediately extruded, or (b) quenched with air or water and later extruded. In either case, the preheat temperature (i.e., the temperature at which the billet enters the extrusion press) can be significantly higher than the preferred maximum temperature of 800°F described in U.S. Patent No. 7,422,645. In one aspect, the preheat temperature is greater than 800°F. In one approach, the preheat temperature ranges from 810°F to 960°F. In one embodiment, the preheat temperature is at least 820°F. In another embodiment, the preheat temperature is at least 830°F. In yet another embodiment, the preheat temperature is at least 840°F. In another embodiment, the preheat temperature is at least 850°F. In yet another embodiment, the preheat temperature is at least 860°F. In another embodiment, the preheat temperature is at least 870°F. In yet another embodiment, the preheat temperature is at least 880°F. In another embodiment, the preheat temperature is at least 890°F. In yet another embodiment, the preheat temperature is at least 900°F. In another embodiment, the preheat temperature is at least 905°F. In yet another embodiment, the preheat temperature is at least 910°F. In another embodiment, the preheat temperature is at least 915°F. In yet another embodiment, the preheat temperature is at least 920°F. In one embodiment, the preheat temperature does not exceed 950°F.

[0044] In one embodiment, the preheat temperature is between 900°F and 960°F. In another embodiment, the preheat temperature is between 905°F and 960°F. In yet another embodiment, the preheat temperature is between 910°F and 960°F. In another embodiment, the preheat temperature is between 915°F and 960°F. In yet another embodiment, the preheat temperature is between 920°F and 960°F.

[0045] In one embodiment, the extrusion speed is between 40 and 70 feet per minute.

[0046] As noted above, the new 6xxx aluminum alloys described herein may facilitate cooler extrusion and / or higher speed extrusion without concomitant material loss of mechanical properties and / or without visually apparent surface defects (e.g., no cracks, hot tears, etc.). Thus, higher throughput may be realized without significantly sacrificing quality.

[0047] In one embodiment, the extrusion process begins at a preheat temperature, and the extrusion method includes extruding the billet into an extrudate. In one embodiment, the method includes quenching the extrudate during the extrusion step (e.g., immediately after the extrudate exits the extrusion apparatus). In another embodiment, the method includes solution heat treating in a separate furnace after the extrusion step, and then quenching the extruded product. In one embodiment, the method includes artificially aging the extruded product. In one embodiment, the method includes cold working the extruded product and then artificially aging the extruded product. In one embodiment, the method includes artificially aging the extruded product and then cold working the extruded product. Natural aging can be used instead of or before artificial aging.

[0048] iii. Microstructure As noted above, the new 6xxx aluminum alloy products may contain high volume fraction dispersoids and / or high volume fraction dispersoids, as defined below. <111> A unique microstructure such as a microtexture can be achieved. <111> The volume fraction of the microtexture shall be determined according to the microstructure evaluation procedure described below.

[0049] In one embodiment, as described above, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.30%, wherein the dispersoids comprise FeMn3Si2 dispersoids. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.35%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.40%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.45%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.50%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.55%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.60%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.65%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.70%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.75%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.80%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.85%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.90%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.95%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 1.0%. In another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 1.05%. In yet another embodiment, the new 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 1.10%.

[0050] In one embodiment, the new 6xxx aluminum alloy products achieve a mean (average) dispersoid size of 0.05 to 0.20 micrometers.

[0051] In one embodiment, the D90 of the dispersoids is 0.30 micrometers or less. In another embodiment, the D90 of the dispersoids is 0.27 micrometers or less. In yet another embodiment, the D90 of the dispersoids is 0.24 micrometers or less. In another embodiment, the D90 of the dispersoids is 0.21 micrometers or less. In yet another embodiment, the D90 of the dispersoids is 0.19 micrometers or less. In another embodiment, the D90 of the dispersoids is 0.18 micrometers or less.

[0052] In one embodiment, the D10 of the dispersoids is at least 0.02 micrometers. In another embodiment, the D10 of the dispersoids is at least 0.03 micrometers. In yet another embodiment, the D10 of the dispersoids is at least 0.04 micrometers.

[0053] In one embodiment, the new 6xxx aluminum alloy product comprises at least 3 volume % <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 5% by volume of <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 7 volume percent of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 9 volume percent of a microtexture. <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 11 volume percent of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 13% by volume of <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 15 volume percent of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 17 volume percent of a microtexture. <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 19 volume percent of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 21% by volume of <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 23 volume % of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 25% by volume of a microtexture. <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 27 volume percent of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 29 volume % of a microtexture. <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 31 volume % of a microtexture. <111> In another embodiment, the new 6xxx aluminum alloy products contain at least 33% by volume of a microtexture. <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 35 volume percent of a microtexture. <111> Contains microtexture.In another embodiment, the new 6xxx aluminum alloy product comprises at least 37 volume % <111> In yet another embodiment, the new 6xxx aluminum alloy products contain at least 39 volume percent of a microtexture. <111> Contains microtexture.

[0054] iv.Characteristics As noted above, the new aluminum alloys may realize improved combinations of properties. For example, products made from the new 6xxx aluminum alloys may realize improved combinations of two or more of strength, ductility (elongation), extrudability, extrusion temperature, extrusion rate, and absence of visually apparent surface defects (e.g., no cracks, hot tears, etc.).

[0055] In one embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 40 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 41 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 42 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 43 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 44 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 45 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 46 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 47 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 48 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 49 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 50 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 51 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 52 ksi. In another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 53 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize a tensile yield strength (LT) of at least 54 ksi. The properties specified in this paragraph may be realized in various tempers, including T5 and T8 tempers.

[0056] In one embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 43 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 44 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 45 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 46 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 47 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 48 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 49 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 50 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 51 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 52 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 53 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 54 ksi. In another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 55 ksi. In yet another embodiment, the new 6xxx aluminum alloy products realize an ultimate tensile strength (LT) of at least 56 ksi. The properties specified in this paragraph may be achieved in various tempers, including T5 and T8 tempers.

[0057] In one embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 8%. In another embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 9%. In yet another embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 10%. In another embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 11%. In yet another embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 12%. In another embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 13%. In yet another embodiment, the new 6xxx aluminum alloy products realize an elongation (LT) of at least 14%. The properties specified in this paragraph may be achieved in various tempers, including T5 and T8 tempers.

[0058] v.Product usage The new 6xxx aluminum alloys described herein may be used in a variety of applications, including those requiring free cutting, i.e., the new 6xxx aluminum alloys may be used as free cutting alloys. In one embodiment, the new 6xxx aluminum alloys are in the form of extruded rods.

[0059] vi.Definition "Wrought aluminum alloy product" means an aluminum alloy product that is hot worked after casting, and includes rolled products (sheet or plate), forged products, and extruded products.

[0060] "Hot working," for example, by hot rolling, means working an aluminum alloy product at an elevated temperature, generally at least 250°F (121.1°C). Strain hardening is limited / avoided during hot working, and generally distinguishes hot working from cold working.

[0061] "Cold working," e.g., by cold rolling, means working an aluminum alloy product at temperatures that are not considered hot working temperatures, generally below about 121.1°C (250°F) (e.g., at ambient temperature).

[0062] The definition of temper is based on ANSI H35.1 (2009) entitled "American National Standard Alloy and Temper Designation Systems for Aluminum" published by the Aluminum Association.

[0063] Strength and elongation are measured according to ASTM E8 / E8M-16a and B557-15.

[0064] vii. Microstructural Evaluation Procedure The microstructural characteristics of the products made in accordance with this patent application (e.g., dispersoid content and size, <111> The following procedures and definitions apply to the measurement of microtexture (volume fraction):

[0065] A. Dispersoid "Dispersoid area fraction" (f) is the fraction of the area covered by dispersoid particles divided by the total area of ​​a 2D cross section prepared by standard metallographic preparation techniques.

[0066] "Dispersoid area %" is calculated by the formula f×100.

[0067] "Dispersoid average diameter" is the sum of all measured dispersoid diameters (d i ), and each diameter is the equivalent diameter calculated by assuming that the area of ​​each dispersoid measured in a two-dimensional cross section is a circle of effective diameter:

number

[0068] To measure the dispersoid area fraction (f) and dispersoid mean diameter, backscattered electron images should be taken at different magnifications and contrast / brightness settings to determine the lowest magnification that adequately captures the smallest size dispersoids. Brightness / contrast settings are determined to be acceptable when the dispersoids are significantly brighter than the background matrix and particle edges are easily discernible. Typically, the on-screen magnification is 1000x to 10,000x. For the images in Example 1 below, the on-screen magnification was 5000x. Dispersoids are imaged using an Apreo S field-emission electron gun (Thermo Fisher Scientific, Waltham, MA, USA) scanning electron microscope, or equivalent. Images should be taken using an accelerating voltage of 5 kV. The beam current should be 0.8 nanoamperes. The working distance should be 5 mm. The dwell time should be 5 microseconds. The line average should be 3. For each alloy, at least 20 images should be collected from a metallographically polished specimen at or near T / 2 or D / 2, as applicable. For each sample, images should be captured from multiple different random locations so that the entire analysis represents the microstructure. Images with scratches, foreign matter, or out-of-focus images should be excluded, but a minimum of 20 acceptable images are still required for analysis. Image analysis to quantify images should use MIPAR version 3.3.4 or equivalent. The pixel size for quantifying dispersoids will vary depending on the magnification and image resolution. A pixel size of 0.008 micrometers was used for the image analysis performed in Example 1. The peak (mode) of the image histogram corresponding to the average background level was 69–71 for 8-bit images ranging from 0 (black) to 255 (white). A pixel is only considered to belong to a dispersoid if its grayscale value is 40% greater than the background, i.e., a global threshold of 100. A particle is not considered to be a dispersoid if its area consists of fewer than 20 adjacent pixels, if the particle is larger than 1500 pixels, or if the average intensity of all pixels within the particle is not 10% greater than the minimum threshold defined above.Prior to analysis, each image frame is reviewed and all non-dispersoid particles are manually removed (non-dispersoid particles may include surface debris such as abrasive compounds, or image artifacts such as charging). A data file (e.g., EXCEL, Microsoft, USA) displaying statistics for each particle is generated. Calculations are performed based on the data file. An equivalent diameter is created for each particle by taking the total particle area and calculating the diameter if the particle were a perfect circle.

[0069] Figure 1B illustrates an example of an image for particle size analysis: Figure 1A is an SEM image processed according to the procedure described above to produce Figure 1B.

[0070] B. <111> Microtexture volume fraction

[0071] " <111> "Percent microtexture" and similar expressions refer to the percentage of microtexture in a wrought aluminum alloy product that is closely aligned with the L direction (e.g., the extrusion direction of an extruded product). <111> It refers to the volume percent (fraction) of a crystallographic direction. <111> The amount of microtexture is determined by EBSD (Electron Backscatter Diffraction) analysis of an appropriate area of ​​the wrought aluminum alloy product. <111> A high amount of microtexture indicates a non-recrystallized microstructure, while <111> A low amount of microtexture indicates a recrystallized microstructure.

[0072] EBSD analysis shall be completed across the full width of the wrought product specimen on the LT-ST plane using the following EBSD specimen procedure. The size of the specimen analyzed generally varies depending on the size and shape of the wrought product, e.g., extrusion profile size and shape. Prior to measurement, the EBSD specimen is prepared using standard metallographic specimen preparation methods. For example, the EBSD specimen is metallographically prepared and then polished (e.g., using 0.05 micron colloidal silica). The specimen is then anodized for 90 seconds with Barker's reagent, a dilute fluoroboric acid solution. The specimen is then stripped using an aqueous phosphoric acid solution containing chromium trioxide, rinsed, and dried.

[0073] The "EBSD sample procedure" is as follows: The software used was APEX EBSD Collection Software version 2 (EDAX Inc., New Jersey, USA) or equivalent, connected to a Velocity EBSD camera (EDAX Inc., New Jersey, USA) or equivalent. The SEM was an APREO S field emission electron gun (Thermo Fisher Scientific, Waltham, MA, USA) or equivalent. The EBSD operating conditions were a tilt of 68°, a working distance of 18 mm, an accelerating voltage of 20 kV, dynamic focusing, and a specific beam current of 26 nA (nanoamperes). The collection mode was a square grid. Orientation was selected to be collected in the analysis (i.e., Hough peak information was not collected). Scans were collected at 120X in 3-micron steps across multiple frames to cover the entire sample width. The APEX software merges the frames together. If it is not possible to scan the entire sample, for example, if the profile dimensions are too large, several separate locations can be mapped, provided that when analyzed together, the results represent an average of competing extrudates. The collected data was output to an *.osc file. This data was used as described below. <111> The volume fraction of the microtexture can be calculated. · <111> Calculation of the microtexture volume fraction: <111> The microtexture volume fraction is calculated using the data in the *.osc file and OIM analysis software (EDAX Inc., New Jersey, USA) version 8.5.1, or equivalent. Prior to calculation, a two-stage data cleanup can be performed. First, for any point with a confidence index below a threshold of 0.10, a neighboring orientation correlation cleanup is performed, requiring five similarly oriented neighbors (out of a possible eight). Next, for any grains with fewer than three data points with a confidence index below a threshold of 0.15, a grain expansion cleanup is performed. Next, <111> The amount of microtexture <111> Calculated by software using microtexture criteria (below). · <111> Microtexture criteria: The crystallographic orientation map was aligned within 10° of the longitudinal axis (e.g., extrusion axis), which corresponds to the normal direction of the EBSD scan in the LT-ST plane. <111> The software calculates the area fraction of all points that fall within this partition. Because crystallographic texture measurements are three-dimensional, the calculated area fraction is equivalent to a volume fraction (volume percent).

[0074] viii. Miscellaneous matters These and other aspects, advantages, and novel features of the new technology are described in part in the description that follows, which will become apparent to those skilled in the art upon examination of the following description and drawings, or may be learned by practicing one or more embodiments of the technology provided by this disclosure.

[0075] Among those benefits and improvements that have been disclosed, other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings. Although detailed embodiments of the present invention are disclosed herein, it should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Furthermore, each of the examples given in connection with various embodiments of the present invention are intended to be illustrative and not limiting.

[0076] Throughout the specification and claims, the following terms take the meanings clearly associated therewith, unless the context clearly dictates otherwise. As used herein, the phrases "in one embodiment" and "in some embodiments" do not necessarily refer to the same embodiment, although they may. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, although they may. Thus, various embodiments of the invention may be readily combined without departing from the scope or spirit of the invention.

[0077] Additionally, as used herein, the term "or" is an inclusive "or" modifier and is equivalent to the term "and / or" unless the context clearly dictates otherwise. The term "based on" is not exclusive and may be based on additional unrecited elements unless the context clearly dictates otherwise. Furthermore, throughout this specification, "a," "an," and "the" include plural meanings unless the context clearly dictates otherwise. "In" includes "in" and "on" meanings unless the context clearly dictates otherwise.

[0078] While several embodiments of the present invention have been described, it should be understood that these embodiments are illustrative only, not limiting, and that many variations may become apparent to those skilled in the art. Moreover, unless the context clearly dictates otherwise, the various steps may be performed in any desired order, and any applicable steps may be added and / or removed. [Brief explanation of the drawings]

[0079] [Figure 1A] FIG. 1A is an SEM image of a representative one of alloys 4 to 6 in Example 1.

[0080] [Figure 1B] FIG. 1B is a processed version of the SEM image of FIG. 1A used for particle (dispersoid) size analysis.

[0081] [Figure 2] FIG. 2 is a graph showing the dispersoid particle size distribution of the alloy of Example 1.

[0082] [Figure 3A] FIG. 3A is a representative microstructure of the standard 6020 alloy from Example 1, taken across the width of the extruded bar and centered at D / 2. The microstructure was generated from EBSD data of points located within 10° of the extrusion axis. <111> This is a crystal orientation map.

[0083] [Figure 3B] FIG. 3B shows representative microstructures of Alloys 1-3 from Example 1, taken across the width of the extruded bar and centered at D / 2. The microstructures were generated from EBSD data of points located within 10° of the extrusion axis. <111> This is a crystal orientation map.

[0084] [Figure 3C] FIG. 3C shows representative microstructures of Alloys 4-6 from Example 1, taken across the width of the extruded bar and centered at D / 2. The microstructures were generated from EBSD data of points located within 10° of the extrusion axis. <111> This is a crystal orientation map. DETAILED DESCRIPTION OF THE INVENTION

[0085] Example 1

[0086] Six commercial-scale billets (11 inches (D) x 40 inches (L), 27.9 cm (D) x 101.6 cm (L)) were cast of the new aluminum alloy shown in Table 1. Three identically sized conventional 6020 billets were also cast, the average compositions of which are shown in Table 1 below. [Table 1]

[0087] After casting, the billets were homogenized and then extruded into 0.637-inch (16.17 mm) diameter coiled bars at a nominal furnace set temperature of 940°F (504°C) and an extrusion rate of 38.5 ft / min (11.58 m / min), followed by water quenching. The extruded bars were then drawn to a final diameter of 0.539 inch (13.7 mm) with a 28.4% ROA (reduction of area) and then aged at 355°F (179.4°C) for 8 hours, thereby producing T8 temper bars. The mechanical properties of the bars were then measured by taking tensile samples from the front and back of each bar. The mechanical property results are summarized in Table 2 below. (Values ​​are the average of duplicate specimens.) [Table 2]

[0088] As shown, the new alloys achieve significantly higher strengths and generally similar ductility than conventional alloy 6020. Alloys 4-6, which contain more silicon (>0.8 wt%) and manganese (>0.3 wt%), achieve significantly higher strengths than conventional alloy 6020.

[0089] Particle counts were also measured on the SEM images following the microstructure evaluation procedure described above. The particle count results are shown in Table 3 below. Figure 2 shows the particle size distribution. The average and D10-D90 values ​​shown below are in micrometers. [Table 3]

[0090] The particle count represents the volume of dispersoids in the alloy product, including the volume of FeMn3Si2 dispersoids. As shown, the new alloy contains significantly more dispersoids than the conventional 6020 alloy, although the dispersoid size is generally similar. It is believed that the higher manganese, iron, and / or silicon content contributes, at least in part, to the high volume fraction of dispersoids in the new aluminum alloy product. Such a high amount of dispersoids may facilitate, among other things, the production of wrought aluminum alloy products in partially or fully unrecrystallized morphologies, which may result in improved properties.

[0091] Microstructural analysis of the produced bars was also performed. Specifically, one bar of alloys 1-3, one bar of alloys 4-6, and one bar of the 6020 alloy were subjected to EBSD imaging according to the microstructural evaluation procedure described above. As shown in Figures 3A-3C, the standard 6020 alloy had very little <111> Contains microtexture (less than 3% by volume) <111> microtexture), which is consistent with a fully recrystallized microstructure. Conversely, the new alloys with at least 0.15 wt.% Mn and 0.40 wt.% Fe exhibit significantly more <111> Alloys 1-3, which contain approximately 0.66 wt% Si, 0.42 wt% Fe, and 0.18 wt% Mn, exhibited a microtexture of approximately 20 vol%. <111> Alloys 4-6, with about 0.81 wt% Si, 0.45 wt% Fe, and 0.32 wt% Mn, contained about 40 vol% Si. <111> It contains microtexture, which is consistent with a microstructure that is not fully recrystallized.

[0092] Example 2

[0093] Additional commercial scale billets were cast and homogenized according to Example 1, the composition of which is shown in Table 4 below. [Table 4]

[0094] The homogenized first set of billets was preheated from room temperature to 940°F (504°C) and then extruded at an extrusion rate of 50 ft / min (15.24 m / min) to a diameter of 1.031 inch (26.2 mm) followed by water quenching. The extruded bars were then drawn to a final diameter of 0.952 inch (24.2 mm) with a 14.6% ROA (reduction of area) and then aged at 355°F (179.4°C) for 8 hours, thereby producing the first set of T8 temper bars (Alloy 7A).

[0095] The second set of homogenized billets was preheated from room temperature to 870°F (465.6°C) and then extruded at a rate of 50 ft / min (15.24 m / min) to a diameter of 1.077 in (27.3 mm) followed by water quenching. The extruded bars were then drawn to a final diameter of 0.953 in (24.2 mm) with a 21.7% ROA (reduction of area) and then aged at 355°F (179.4°C) for 8 hours, thereby producing T8 temper bars (Alloy 7B).

[0096] The mechanical properties of the bars were then measured by taking tensile samples from the front and back of each bar. The mechanical property results are summarized in Table 5 below. (Values ​​are the average of at least triplicate specimens.) [Table 5]

[0097] It is believed that the high amount of dispersoids facilitates, among other things, the production of partially or fully unrecrystallized rods, resulting in improved mechanical properties. For example, Alloy 7 contained 0.12 wt. % Cr compared to 0.05-0.06 wt. % Cr in Alloys 1-6. The increased amount of chromium in Alloy 7 may be at least partially responsible for its significantly higher strength properties.

[0098] While various embodiments of the present disclosure have been described in detail, it is apparent that variations and modifications to those embodiments will occur to those skilled in the art, but it should be expressly understood that such variations and modifications are within the spirit and scope of the present disclosure.

Claims

1. 0.5 to 1.5 wt. % Sn, 0.4 to 1.6 wt.% Si, 0.6 to 1.2 wt.% Mg wherein the weight ratio of (wt. % Si) to (wt. % Mg) is at least 0.75:1; 0.5 to 1.1 wt. % Cu, 0.15 to 1.5 wt. % Mn, 0.10 to 0.80 wt. % Fe wherein (wt. % Si) + (wt. % Mn) + (wt. % Fe) is at least 0.95 wt. %; maximum 1.2 wt.% Bi, up to 1.2 wt.% In, Zn up to 1.0 wt.%; 0.35 wt.% max Cr, maximum 0.25 wt.% V, up to 0.25 wt.% Zr, maximum 0.15 wt.% Ti, 6xxx aluminum alloy product containing up to 0.04 wt.% Pb, the balance being aluminum, optional incidental elements, and impurities; the 6xxx aluminum alloy product comprises a dispersoid area fraction (f) of at least 0.30%, the dispersoids being FeMn ３ Si ２ 6xxx aluminum alloy products containing dispersoids.

2. 2. The 6xxx aluminum alloy product of claim 1, wherein the 6xxx aluminum alloy product comprises at least 0.55 wt.% Sn, or at least 0.60 wt.% Sn, or at least 0.65 wt.% Sn, or at least 0.70 wt.% Sn, or at least 0.75 wt.% Sn, or at least 0.80 wt.% Sn, or at least 0.85 wt.% Sn, or at least 0.90 wt.% Sn, or at least 0.95 wt.% Sn, or at least 1.0 wt.% Sn, or at least 1.05 wt.% Sn, or at least 1.10 wt.% Sn.

3. 3. The 6xxx aluminum alloy product of any one of claims 1 and 2, wherein the 6xxx aluminum alloy product contains up to 1.45 wt.% Sn, or up to 1.40 wt.% Sn, or up to 1.35 wt.% Sn, or up to 1.30 wt.% Sn.

4. 4. The 6xxx aluminum alloy product of any one of claims 1 - 3, wherein the 6xxx aluminum alloy product comprises at least 0.45 wt.% Si, or at least 0.50 wt.% Si, or at least 0.55 wt.% Si, or at least 0.60 wt.% Si, or at least 0.65 wt.% Si, or at least 0.70 wt.% Si, or at least 0.75 wt.% Si, or at least 0.80 wt.% Si.

5. 5. The 6xxx aluminum alloy product of any one of claims 1 - 4, wherein the 6xxx aluminum alloy product contains up to 1.55 wt% Si, or up to 1.50 wt% Si, or up to 1.45 wt% Si, or up to 1.40 wt% Si, or up to 1.35 wt% Si, or up to 1.30 wt% Si, or up to 1.25 wt% Si, or up to 1.20 wt% Si, or up to 1.15 wt% Si, or up to 1.10 wt% Si, or up to 1.05 wt% Si, or up to 1.0 wt% Si, or up to 0.95 wt% Si, or up to 0.90 wt% Si.

6. 6. The 6xxx aluminium alloy product of any one of the preceding claims, wherein the 6xxx aluminium alloy product comprises at least 0.65wt.% Mg, or at least 0.70wt.% Mg.

7. 7. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product contains up to 1.15wt% Mg, or up to 1.10wt% Mg, or up to 1.05wt% Mg, or up to 1.0wt% Mg, or up to 0.95wt% Mg, or up to 0.90wt% Mg, or up to 0.85wt% Mg.

8. The 6xxx aluminium alloy product according to any one of the preceding claims, wherein the weight ratio of (wt. % Si) to (wt. % Mg) is at least 0.80:1, or at least 0.85:1, or at least 0.90:1, or at least 0.95:1, or at least 1.0:1, or at least 1.05:1, or at least 1.10:1, or at least 1.15:

1.

9. 9. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the weight ratio of (wt. % Si) to (wt. % Mg) is no more than 2.2:1, or no more than 2.1:1, or no more than 2.0:1, or no more than 1.9:1, or no more than 1.8:1, or no more than 1.7:1, or no more than 1.6:1, or no more than 1.5:1, or no more than 1.4:1, or no more than 1.3:1, or no more than 1.2:

1.

10. 10. The 6xxx aluminium alloy product of any one of the preceding claims, wherein (wt.% Si)+(wt.% Mg) is at least 1.3wt.%, or at least 1.35wt.%, or at least 1.40wt.%, or at least 1.45wt.%, or at least 1.50wt.%, or at least 1.55wt.%, or at least 1.60wt.%, or at least 1.65wt.%, or at least 1.70wt.%.

11. 11. The 6xxx aluminum alloy product of any one of the preceding claims, wherein (wt.% Si) + (wt.% Mg) is equal to or less than 2.6 wt.%, or equal to or less than 2.5 wt.%, or equal to or less than 2.4 wt.%, or equal to or less than 2.3 wt.%, or equal to or less than 2.2 wt.%, or equal to or less than 2.1 wt.%, or equal to or less than 2.0 wt.%, or equal to or less than 1.9 wt.%, or equal to or less than 1.85 wt.%, or equal to or less than 1.8 wt.%, or equal to or less than 1.75 wt.%.

12. 12. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.55 wt.% Cu, or at least 0.60 wt.% Cu, or at least 0.65 wt.% Cu.

13. 13. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises up to 1.05 wt.% Cu, or up to 1.0 wt.% Cu, or up to 0.95 wt.% Cu, or up to 0.90 wt.% Cu, or up to 0.85 wt.% Cu, or up to 0.80 wt.% Cu, or up to 0.75 wt.% Cu.

14. 14. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.18 wt% Mn, or at least 0.20 wt% Mn, or at least 0.22 wt% Mn, or at least 0.24 wt% Mn, or at least 0.26 wt% Mn, or at least 0.28 wt% Mn, or at least 0.30 wt% Mn, or at least 0.32 wt% Mn, or at least 0.34 wt% Mn, or at least 0.36 wt% Mn, or at least 0.38 wt% Mn, or at least 0.40 wt% Mn.

15. the 6xxx aluminum alloy product contains not more than 1.45 wt% Mn, or not more than 1.40 wt% Mn, or not more than 1.35 wt% Mn, or not more than 1.30 wt% Mn, or not more than 1.25 wt% Mn, or not more than 1.20 wt% Mn, or not more than 1.15 wt% Mn, or not more than 1.10 wt% Mn, or not more than 1.05 wt% Mn, or not more than 1.0 wt% Mn, or not more than 0.95 wt% Mn, or not more than 0.90 wt% Mn.

15. The 6xxx aluminum alloy product of any one of claims 1 to 14, wherein the 6xxx aluminum alloy product contains less than 0.85 wt% Mn, or not more than 0.80 wt% Mn, or not more than 0.75 wt% Mn, or not more than 0.70 wt% Mn, or not more than 0.65 wt% Mn, or not more than 0.60 wt% Mn, or not more than 0.55 wt% Mn, or not more than 0.50 wt% Mn, or not more than 0.45 wt% Mn, or not more than 0.42 wt% Mn.

16. 16. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.15 wt.% Fe, or at least 0.20 wt.% Fe, or at least 0.25 wt.% Fe, or at least 0.30 wt.% Fe, or at least 0.35 wt.% Fe, or at least 0.40 wt.% Fe, or at least 0.45 wt.% Fe, or at least 0.50 wt.% Fe.

17. 17. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises up to 0.75% Fe, or up to 0.70% Fe, or up to 0.65% Fe, or up to 0.60% Fe, or up to 0.55% Fe, or up to 0.52% Fe.

18. 18. The 6xxx aluminium alloy product of any one of the preceding claims, wherein (wt.% Si) + (wt.% Mn) + (wt.% Fe) is at least 1.0 wt.%, or at least 1.05 wt.%, or at least 1.10 wt.%, or at least 1.15 wt.%, or at least 1.20 wt.%, or at least 1.25 wt.%, or at least 1.30 wt.%, or at least 1.35 wt.%, or at least 1.40 wt.%, or at least 1.45 wt.%, or at least 1.50 wt.%, or at least 1.55 wt.%, or at least 1.60 wt.%.

19. 19. The 6xxx aluminum alloy product of any one of the preceding claims, wherein (wt.% Si) + (wt.% Mn) + (wt.% Fe) is equal to or less than 3.1 wt.%, or equal to or less than 3.0 wt.%, or equal to or less than 2.9 wt.%, or equal to or less than 2.8 wt.%, or equal to or less than 2.7 wt.%, or equal to or less than 2.6 wt.%, or equal to or less than 2.5 wt.%, or equal to or less than 2.4 wt.%, or equal to or less than 2.3 wt.%, or equal to or less than 2.2 wt.%, or equal to or less than 2.1 wt.%, or equal to or less than 2.0 wt.%, or equal to or less than 1.9 wt.%, or equal to or less than 1.8 wt.%, or equal to or less than 1.7 wt.%.

20. The 6xxx aluminum alloy product contains not more than 1.1 wt% Bi, or not more than 1.0 wt% Bi, or not more than 0.9 wt% Bi, or not more than 0.8 wt% Bi, or not more than 0.7 wt% Bi, or not more than 0.6 wt% Bi, or not more than 0.50 wt% Bi, or not more than 0.40 wt% Bi, or not more than 0.30 wt% Bi, or not more than 0.20 wt% Bi, or not more than 0.15 wt% Bi, or not more than 0.10 wt% Bi, or not more than 0.08 wt% Bi, or not more than 0.05 wt% Bi, or not more than 0.03 wt% Bi, or not more than 0.01 wt% Bi, or not more than 0.005 wt% Bi. The 6xxx aluminum alloy product of any one of claims 1 to 19.

21. 21. The 6xxx aluminum alloy of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.25 wt.% Bi, wherein bismuth at least partially substitutes for tin.

22. 22. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises not more than 1.1 wt% In, or not more than 1.0 wt% In, or not more than 0.9 wt% In, or not more than 0.8 wt% In, or not more than 0.7 wt% In, or not more than 0.6 wt% In, or not more than 0.50 wt% In, or not more than 0.40 wt% In, or not more than 0.30 wt% In, or not more than 0.20 wt% In, or not more than 0.15 wt% In, or not more than 0.10 wt% In, or not more than 0.08 wt% In, or not more than 0.05 wt% In, or not more than 0.03 wt% In, or not more than 0.01 wt% In, or not more than 0.005 wt% In.

23. 23. The 6xxx aluminum alloy of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.25 wt. % In, wherein indium at least partially substitutes for tin.

24. 24. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product contains up to 0.9 wt% Zn, or up to 0.8 wt% Zn, or up to 0.7 wt% Zn, or up to 0.6 wt% Zn, or up to 0.5 wt% Zn, or up to 0.4 wt% Zn, or up to 0.3 wt% Zn, or up to 0.20 wt% Zn, or up to 0.15 wt% Zn, or up to 0.10 wt% Zn, or up to 0.08 wt% Zn, or up to 0.05 wt% Zn, or up to 0.03 wt% Zn.

25. 25. The 6xxx aluminium alloy product of any one of the preceding claims, wherein the 6xxx aluminium alloy product comprises at least 0.01 wt.% Zn.

26. 26. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.01 wt.% Cr, or at least 0.03 wt.% Cr, or at least 0.06 wt.% Cr, or at least 0.08 wt.% Cr, or at least 0.10 wt.% Cr, or at least 0.12 wt.% Cr, or at least 0.14 wt.% Cr, or at least 0.16 wt.% Cr, or at least 0.18 wt.% Cr.

27. 27. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises up to 0.30 wt.% Cr, or up to 0.25 wt.% Cr, or up to 0.22 wt.% Cr, or up to 0.20 wt.% Cr.

28. 28. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product contains up to 0.15 wt% V, or up to 0.10 wt% V, or up to 0.08 wt% V, or up to 0.05 wt% V, or up to 0.03 wt% V, or up to 0.01 wt% V, or up to 0.005 wt% V.

29. 10. The 6xxx aluminum alloy product of claim 1, wherein the 6xxx aluminum alloy product comprises at least 0.01 wt.% V.

30. 30. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises up to 0.15 wt% Zr, or up to 0.10 wt% Zr, or up to 0.08 wt% Zr, or up to 0.05 wt% Zr, or up to 0.03 wt% Zr, or up to 0.01 wt% Zr, or up to 0.005 wt% Zr.

31. 10. The 6xxx aluminum alloy product of claim 1, wherein the 6xxx aluminum alloy product comprises at least 0.01 wt.% Zr.

32. The 6xxx aluminum alloy product of any one of claims 28 to 31, wherein at least one of Zr and V partially substitutes for Cr.

33. 33. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises up to 0.12 wt% Ti, or up to 0.10 wt% Ti, or up to 0.08 wt% Ti, or up to 0.07 wt% Ti, or up to 0.06 wt% Ti, or up to 0.05 wt% Ti.

34. 34. The 6xxx aluminium alloy product of any one of the preceding claims, wherein the 6xxx aluminium alloy product comprises at least 0.01 wt.% Ti, or at least 0.02 wt.% Ti, or at least 0.03 wt.% Ti.

35. 35. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product contains up to 0.03 wt.% Pb, or up to 0.01 wt.% Pb, or up to 0.005 wt.% Pb.

36. 36. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product contains not more than 0.15% by weight of total impurities, and wherein the 6xxx aluminum alloy product contains not more than 0.05% by weight of each impurity, or wherein the 6xxx aluminum alloy product contains not more than 0.10% by weight of total impurities, and wherein the 6xxx aluminum alloy product contains not more than 0.03% by weight of each impurity.

37. 37. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the dispersoid area fraction (f) is at least 0.35%, or at least 0.40, or at least 0.45, or at least 0.50, or at least 0.55, or at least 0.60, or at least 0.65, or at least 0.70, or at least 0.75, or at least 0.80, or at least 0.85, or at least 0.90, or at least 0.95, or at least 1.0, or at least 1.05, or at least 1.

10.

38. The 6xxx aluminium alloy product of any one of the preceding claims, wherein the mean dispersoid size is from 0.05 to 0.20 micrometers.

39. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the dispersoids have a D90 of no more than 0.30 micrometers, or no more than 0.27 micrometers, or no more than 0.24 micrometers, or no more than 0.21 micrometers, or no more than 0.19 micrometers, or no more than 0.18 micrometers.

40. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the dispersoids have a D10 of at least 0.02 micrometers, or at least 0.03 micrometers, or at least 0.04 micrometers.

41. the 6xxx aluminum alloy product has at least 3% by volume <111> microtexture, or at least 5% by volume <111> microtexture, or at least 7% by volume <111> microtexture, or at least 9% by volume <111> microtexture, or at least 11% by volume <111> microtexture, or at least 13% by volume <111> microtexture, or at least 15% by volume <111> microtexture, or at least 17% by volume <111> microtexture, or at least 19% by volume <111> microtexture, or at least 21% by volume <111> microtexture.

41. The 6xxx aluminum alloy product of any one of claims 1 to 40, comprising at least 23 vol.% <111> microtexture, or at least 25 vol.% <111> microtexture, or at least 27 vol.% <111> microtexture, or at least 29 vol.% <111> microtexture, or at least 31 vol.% <111> microtexture, or at least 33 vol.% <111> microtexture, or at least 35 vol.% <111> microtexture, or at least 37 vol.% <111> microtexture, or at least 39 vol.% <111> microtexture.

42. 42. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product realizes a tensile yield strength (LT) of at least 40 ksi, or at least 41 ksi, or at least 42 ksi, or at least 43 ksi, or at least 44 ksi, or at least 45 ksi, or at least 46 ksi, or at least 47 ksi, or at least 48 ksi, or at least 49 ksi, or at least 50 ksi, or at least 51 ksi, or at least 52 ksi, or at least 53 ksi.

43. 43. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product realizes an ultimate tensile strength (LT) of at least 43 ksi, or at least 44 ksi, or at least 45 ksi, or at least 46 ksi, or at least 47 ksi, or at least 48 ksi, or at least 49 ksi, or at least 50 ksi, or at least 51 ksi, or at least 52 ksi, or at least 53 ksi, or at least 54 ksi, or at least 55 ksi, or at least 56 ksi.

44. 44. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product realizes an elongation (LT) of at least 8%, or at least 9%, or at least 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%.

45. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product is a sheet, plate, extrusion, or forging.

46. The 6xxx aluminum alloy product of any one of the preceding claims, wherein the 6xxx aluminum alloy product is an extrusion.

47. 45. The 6xxx aluminum alloy product of claim 44, wherein said extrusion is a rod.

48. Casting a billet of the 6xxx aluminum alloy of any one of claims 1 to 41; and preheating the billet to an extrusion temperature, wherein the extrusion temperature is between 810°F and 960°F; and extruding the billet into an extruded product.

49. 49. The method of claim 48, comprising quenching the extruded product during the extrusion process.

50. 49. The method of claim 48, further comprising, after the extrusion step, performing a solution heat treatment and then quenching the extruded product.

51. 51. A method according to any one of claims 49 to 50, comprising artificially ageing the extruded product.

52. 51. A method according to any one of claims 48 to 50, comprising cold working the extruded product and then artificially ageing the extruded product.

53. 51. A method according to any one of claims 48 to 50, comprising artificially ageing the extruded product and then cold working the extruded product.

54. 54. The method of any one of claims 48 to 53, wherein the extrusion speed is from 40 to 70 feet per minute.

55. 55. The method of claim 54, wherein the extruded product is free of visually apparent surface defects.

56. 56. The method of any one of claims 48 to 55, wherein the extrusion temperature is at least 820°F, or at least 830°F, or at least 840°F, or at least 850°F, or at least 860°F, or at least 870°F, or at least 880°F, or at least 8980°F, or at least 900°F, or at least 905°F, or at least 910°F, or at least 915°F, or at least 920°F.

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