Clad composites, articles formed from clad composites, methods of forming clad composites, and methods of forming articles

Abstract

Clad composites, articles formed from clad composites, methods of forming clad composites, and methods of forming articles are provided. The clad composites include a core layer and a first layer. The core layer includes a first aluminum alloy having a first corrosion potential. The first layer includes a second aluminum alloy having a second corrosion potential. The second aluminum alloy includes 0 to 0.5 weight percent Zn. The second corrosion potential is in the range of -600 mV to -800 mV. The first corrosion potential is at least 8 mV, but not more than 100 mV, less electronegative than the second corrosion potential.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to clad composites, articles formed from clad composites, methods of forming clad composites, and methods of forming articles. [Background technology]

[0002] Various devices, such as heat exchangers, can be formed from tubes and fins. Heat exchangers function by circulating a fluid within the tubes and allowing heat exchange through the fins to the surrounding environment. To ensure that the heat exchanger has an acceptable operating life, the heat exchanger can be designed to withstand corrosive attack. Increasing resistance to corrosive attack in heat exchangers can present a significant challenge. Summary of the Invention

[0003] One non-limiting embodiment of the present disclosure is directed to a clad composite including a core layer and a first layer. The core layer includes a first aluminum alloy having a first corrosion potential. The first layer includes a second aluminum alloy having a second corrosion potential. The second aluminum alloy includes 0 to 0.5 weight percent Zn. The second corrosion potential is in the range of -600 mV to -800 mV. The first corrosion potential is at least 8 mV, but not more than 100 mV, less electronegative than the second corrosion potential.

[0004] It should be understood that the invention disclosed and described herein is not limited to the aspects summarized in this Summary. The reader will understand these details, as well as others, in light of the following detailed description of various non-limiting and non-exhaustive aspects hereof.

[0005] The features and advantages of the embodiments, and the manner in which they are achieved, will become more apparent and the embodiments will be better understood by referring to the following description in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic side view of a non-limiting embodiment of a clad composite according to the present disclosure. [Figure 2] FIG. 2 is a schematic side view of a non-limiting embodiment of a clad composite according to the present disclosure. [Figure 3] FIG. 3 is a schematic side view of a non-limiting embodiment of an article including a clad composite according to the present disclosure. [Figure 4] FIG. 4 is a block diagram of a non-limiting embodiment of a clad composite and a method according to the present disclosure for forming an article from the clad composite. [Figure 5] FIG. 5 is a schematic perspective view of a tube including a clad composite according to a non-limiting embodiment of the present disclosure. [Figure 6] FIG. 6 is a schematic perspective view of a heat exchanger including tubes comprising a clad composite according to a non-limiting embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0007] The exemplifications set forth herein illustrate particular embodiments in one form, and such exemplifications should not be construed in any way as limiting the scope of the appended claims.

[0008] Various embodiments are described and illustrated herein to provide a comprehensive understanding of the structure, function, and use of the disclosed articles and methods. The various embodiments described and illustrated herein are non-limiting and non-exhaustive. Therefore, the present invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the present invention is defined solely by the claims. Features and characteristics illustrated and / or described in connection with various embodiments may be combined with features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. Accordingly, the claims may be amended to recite any feature or characteristic explicitly or inherently described or otherwise explicitly or inherently supported herein. Furthermore, applicants reserve the right to amend the claims to affirmatively disclaim any feature or characteristic that may exist in the prior art. The various embodiments disclosed and described herein may comprise, consist of, or consist essentially of the features and characteristics variously described herein.

[0009] References herein to "various non-limiting embodiments," "some non-limiting embodiments," "one non-limiting embodiment," "one non-limiting embodiment," or similar phrases mean that a particular feature, structure, or characteristic described in connection with an example is included in at least one embodiment. Thus, appearances of the phrases "in various non-limiting embodiments," "in some non-limiting embodiments," "in one non-limiting embodiment," "in one non-limiting embodiment," or similar phrases herein do not necessarily refer to the same embodiment. Furthermore, particular described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, a particular feature, structure, or characteristic illustrated or described in connection with one non-limiting embodiment may be combined, in whole or in part, without limitation, with a feature, structure, or characteristic of one or more other non-limiting embodiments. Such modifications and variations are intended to be within the scope of the present non-limiting embodiments.

[0010] Various non-limiting embodiments of the alloys described in connection with the present disclosure optionally include the intentional addition of accessory elements that, for example, can aid in the production of the alloy and / or improve one or more properties or characteristics of the alloy. For example, certain non-limiting embodiments of alloys according to the present disclosure may include the intentional incidental addition of one or more grain refiners and / or one or more deoxidizers. In various non-limiting embodiments, the total concentration of accessory elements in an alloy according to the present disclosure preferably does not exceed 1 weight percent based on the total weight of the alloy, and the concentration of any single accessory element preferably does not exceed 0.2 weight percent based on the total weight of the alloy.

[0011] Various non-limiting embodiments of the alloys described in connection with the present disclosure may include impurities. As used herein, an "impurity" is an element or other substance that may be present in relatively low concentrations in alloys according to the present disclosure, but that is not intentionally added to improve the manufacturability of the alloy or to affect the properties or characteristics of the alloy. For example, impurities in alloys according to the present disclosure may be present in low concentrations due to, for example, the unavoidable or unintentional presence of impurities in feed materials, local atmospheric contamination during melting and refining, or contamination from contact with processing equipment. In various non-limiting embodiments, the total concentration of impurities in the alloys described in the present disclosure preferably does not exceed 0.15 weight percent based on the total weight of the alloy, and the concentration of any single impurity preferably does not exceed 0.05 weight percent based on the total weight of the alloy.

[0012] Clad composites can be susceptible to galvanic corrosion (bimetallic corrosion) due to the galvanic difference (potential difference between dissimilar metals) between the composition of the clad composite and the composition of a material joined (e.g., galvanically bonded) to the clad composite. As used herein, "galvanic difference" refers to the corrosion potential difference (e.g., corrosion potential difference) between one region (e.g., layer) and another region. The corrosion potential difference between regions can be due to differences in the compositions of the regions. Without being bound by a particular mechanism or theory, in some non-limiting embodiments, when two regions having a corrosion potential difference are connected together and in the presence of an electrolyte, one region acts as the anode of the galvanic circuit and the other region acts as the cathode of the galvanic circuit. As used herein, "anodic" or "anode" refers to a region having a more electronegative composition than another region. As used herein, "cathodic" or "cathode" refers to a region having a less electronegative composition than another region. As used herein, "more electronegative" means that a corrosion potential value is more negative than another corrosion potential value (e.g., a corrosion potential value of -900 mV is more electronegative than a corrosion potential value of -740 mV). Also, as used herein, "less electronegative" means that a corrosion potential value is more positive than another corrosion potential value (e.g., a corrosion potential value of -740 mV is less electronegative than a corrosion potential value of -900 mV). Corrosion potential may be measured according to ASTM G69-20.

[0013] To improve the corrosion resistance of clad composites and thereby extend the operational life of articles including the clad composites, the present disclosure provides novel clad composites, articles formed from the clad composites, methods of forming clad composites, and methods of forming articles. An embodiment of a clad composite according to the present disclosure includes a core layer and a first layer. The core layer includes a first aluminum alloy having a first corrosion potential. The first layer includes a second aluminum alloy having a second corrosion potential. The second corrosion potential is in the range of -600 mV to -800 mV. The first corrosion potential is at least 8 mV, but not more than 100 mV, less electronegative than the second corrosion potential.

[0014] As used herein, the terms "core" or "core layer" refer to a substrate layer of a clad composite. In various non-limiting embodiments, the "core layer" can be disposed substantially at the center of the clad composite. However, the location of the core layer within a clad composite according to the present disclosure is not limited to the center of the clad composite. The core layer may or may not be covered on both sides by another layer of the clad composite; for example, the core layer may be disposed on one side of the clad composite. Thus, in various non-limiting embodiments, the core layer can be surrounded by other layers of the clad composite, have at least one side partially exposed, or have at least one side fully exposed.

[0015] With reference to FIG. 1 , a clad composite 100 according to the present disclosure is provided. The clad composite 100 includes a core layer 102 and a first layer 104 disposable on the core layer 102. In various non-limiting embodiments, with reference to FIG. 1 , the core layer 102 and the first layer 104 can be bonded together and in contact with each other within the clad composite 100. With further reference to FIG. 2 , optionally, in certain non-limiting embodiments, a clad composite 200 according to the present disclosure can include the core layer 102, the first layer 104, and a second layer 106 disposed intermediate the core layer 102 and the first layer 104. With reference to various non-limiting embodiments, with reference to FIG. 2 , the core layer 102, the first layer 104, and the second layer 106 can be bonded together within the clad composite 200, and the second layer 106 can be in contact with the core layer 102 and the first layer 104. In certain non-limiting embodiments, the clad composite 100 may include layers in addition to the core layer 102 , the first layer 104 , and the second layer 106 .

[0016] Referring to FIG. 3 , article 300 can include clad composite 100 and / or clad composite 200 (not shown) bonded to a second material, such as fin 308. Fin 308 can include a 1XXX series aluminum alloy or a 3XXX series aluminum alloy, each such aluminum alloy containing, by weight percent, 0.25 or less Zn, e.g., 0.2 or less Zn, 0.15 or less Zn, 0.1 or less Zn, 0.05 or less Zn, or 0.01 or less Zn. A low concentration of Zn can allow for more efficient recycling of the fin and / or the use of various grades of aluminum alloys. In some past examples, relatively large amounts of Zn have been added to fins to increase the corrosion potential of the fin and enhance the fin's self-corrosion resistance.

[0017] In various non-limiting embodiments, due to the low concentration of Zn in the fin, the corrosion potential of the fin 308 may not be as electronegative as desired, causing the fin 308 to be anodic relative to the clad composite 100, 200. For example, the corrosion potential of the fin 308 may be in a range of −740 millivolts (mV) to −900 mV, e.g., −740 mV to −850 mV, −740 mV to −800 mV, or −740 mV to −780 mV. Typically, the corrosion potential of corrosion-resistant fins is significantly greater than −900 mV, so layers with corrosion potential values ​​more electronegative than −800 mV (e.g., −850 mV) will still be cathodic relative to the fin.

[0018] To enhance the corrosion resistance of the clad composite 100, 200, the corrosion potentials of the layers within the clad composite 100 can be selected to achieve the desired corrosion resistance. For example, the clad composite 100 can be cathodic relative to the fin 308 in a galvanic circuit, such that the fin 308 corrodes preferentially. In various non-limiting embodiments, a large corrosion potential difference between the fin 308 and the clad composite 100, 200 can lead to rapid corrosion of the fin 308, for example, the fin 308 may exhibit undesirable self-corrosion resistance due to a low or absent concentration of Zn. The corrosion potential of the clad composite 100, 200 can be selected based on the corrosion potential of the fin 308, such that the fin 308 corrodes preferentially at an appropriate rate.

[0019] 1-3, the core layer 102 includes a first aluminum alloy having a first corrosion potential, and the first layer 104 includes a second aluminum alloy having a second corrosion potential. In various non-limiting embodiments, the first corrosion potential is less electronegative than the second corrosion potential to achieve a galvanic potential gradient from the first layer 104 to the core layer 102. For example, the first corrosion potential may be at least 8 mV, e.g., at least 10 mV, at least 20 mV, at least 30 mV, or at least 40 mV, less electronegative than the second corrosion potential. The first corrosion potential may be 100 mV or less, e.g., 90 mV or less, 80 mV or less, 70 mV or less, 60 mV or less, 50 mV or less, 40 mV or less, or 30 mV or less, less electronegative than the second corrosion potential.

[0020] The second corrosion potential can be selected based on a desired application, such as when attaching the clad composite 100, 200 to a fin 308. For example, in various non-limiting embodiments, the second corrosion potential can be in a range of −600 mV to −800 mV, e.g., −680 mV to −740 mV, −690 mV to −730 mV, −700 mV to −730 mV, −715 mV to −730 mV, or −720 mV to −730 mV. In various non-limiting embodiments, the first corrosion potential can be in the range of -590 mV to -750 mV, e.g., -620 mV to -730 mV, -630 mV to -720 mV, -650 mV to -720 mV, -690 mV to -720 mV, -690 mV to -710 mV, or less than -695 mV to -720 mV.

[0021] Referring to FIG. 2 , the second layer 106 includes a third aluminum alloy having a third corrosion potential. The third corrosion potential can be selected to be more electronegative than the first corrosion potential and less electronegative than the second corrosion potential. In various non-limiting embodiments, regardless of the number of layers in the clad composite 100, a galvanic potential gradient can be configured within the clad composite 100 such that the core layer 102 is the most cathodic of the layers and the first layer 104 is the most anodic of the layers. In various non-limiting embodiments, the third corrosion potential can be in a range of −600 mV to −800 mV, e.g., −680 mV to −740 mV, −690 mV to −730 mV, −700 mV to −730 mV, or −715 mV to −730 mV.

[0022] 1-3, to form a galvanic circuit within the clad composite 100, the core layer 102 includes a first concentration of a first cathodic material, the first layer 104 includes a second concentration of a second cathodic material, and the second layer 106 includes a third concentration of a third cathodic material. The first concentration can be greater than the second concentration. The third concentration can be greater than the second concentration and less than the first concentration. As used herein, a "cathodic material" can be an element or combination of elements that, when present in a layer, can make the corrosion potential of the respective layer more electronegative.

[0023] The first, second, and third cathode materials can be the same or different and, in various non-limiting embodiments, are each independently selected from the group consisting of Cu, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, Li, and combinations of two or more thereof. In various examples, the first, second, and third cathode materials can be the same to limit interdiffusion between layers in the brazing sheet during the brazing cycle. In various non-limiting embodiments, the first, second, and third cathode materials are independently selected from the group consisting of Cu, Zn, and Mg. In various non-limiting embodiments, the first, second, and third cathode materials are a mixture of at least two elements independently selected from the group consisting of Cu, Zn, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, and Li.

[0024] In certain non-limiting embodiments, the first cathode material, the second cathode material, and the third cathode material are Cu. Cu can lower the electronegativity of the corrosion potential of each layer and provide solid solution strengthening to each layer. In various non-limiting embodiments, the copper concentration may be limited to 1 wt. % or less to inhibit precipitation, which can adversely affect the self-corrosion resistance of each layer.

[0025] In various non-limiting embodiments, the first concentration can be at least 0.1 weight percent greater than the second concentration, e.g., at least 0.15 weight percent, at least 0.2 weight percent, or at least 0.25 weight percent. In various non-limiting embodiments, the second concentration can be at least 0.05 weight percent greater than the third concentration, e.g., at least 0.1 weight percent, at least 0.15 weight percent, or at least 0.2 weight percent. In various non-limiting embodiments, the core layer 102 includes at least 0.5 weight percent of the first cathode material. In various non-limiting embodiments in which the first, second, and third cathode materials are Cu, the first concentration can be in the range of 0.5 to 1 weight percent Cu, the second concentration can be in the range of 0.25 to 0.5 weight percent Cu, and the third concentration can be in the range of 0.3 to 0.7 weight percent Cu. In various non-limiting embodiments, beginning with the core layer 102 and progressing through the thickness of the clad composite 100 toward the first layer 104, the concentration of cathode material increases with each subsequent layer.

[0026] 1-3, the core layer 102 of the clad composite 100, 200 includes a first aluminum alloy, which may be, for example, a 1XXX series aluminum alloy, a 3XXX series aluminum alloy, a 5XXX series aluminum alloy, or a 6XXX series aluminum alloy. In various non-limiting embodiments, the first aluminum alloy includes, in weight percent, 0.05-1.5 Si, 0-0.8 Fe, 0.5-1.0 Cu, 0.5-1.8 Mn, 0-0.2 Mg, 0-0.25 Zn, 0-0.25 Cr, 0-0.15 Zr, aluminum, and optionally incidental elements and impurities. In some non-limiting embodiments, the first aluminum alloy includes, in weight percent, 0.05-0.95 Si, 0-0.8 Fe, 0.7-1.0 Cu, 1.25-1.8 Mn, 0-0.15 Mg, 0-0.15 Zn, 0-0.15 Cr, 0-0.1 Zr, aluminum, and optionally incidental elements and impurities.

[0027] 1-3, the first layer 104 of the clad composite 100, 200 includes a second aluminum alloy, which may be, for example, a 1XXX series aluminum alloy or a 3XXX series aluminum alloy. In various non-limiting embodiments, the second aluminum alloy includes, in weight percent, 0.05-1.0 Si, 0.25-0.5 Cu, 0-0.5 Zr, 0-0.8 Fe, 0.1-1.5 Mn, 0-0.25 Zn, 0-0.2 Mg, 0-0.2 Ti, 0-1 Cr, 0-0.5 Bi, aluminum, optionally incidental elements, and impurities. In various non-limiting embodiments, the second aluminum alloy includes, in weight percent, 0.05-1.0 Si, 0.25-0.5 Cu, 0-0.5 Zr, 0-0.8 Fe, 0.1-1.5 Mn, 0-0.1 Zn, 0-0.1 Mg, 0-0.2 Ti, 0-1 Cr, 0-0.5 Bi, aluminum, optionally incidental elements, and impurities. In various non-limiting embodiments, the second aluminum alloy includes, in weight percent, 0-0.5 Zn, e.g., 0-0.25 Zn, 0-0.1 Zn, or 0-0.5 Zn.

[0028] Referring to FIG. 2, the second layer 106 of the clad composite 200 comprises a third aluminum alloy, for example, an aluminum alloy containing, in weight percent, 0.05-1.0 Si, 0.25-0.5 Cu, 0-0.5 Zr, 0-0.8 Fe, 0.1-1.5 Mn, 0-0.25 Zn, 0-0.2 Mg, 0-0.2 Ti, 0-1 Cr, 0-0.5 Bi, aluminum, optionally incidental elements, and impurities.

[0029] 1-2, the thickness of each layer within clad composite 100 can be configured based on the desired structural properties of the article being fabricated from or incorporating clad composite 100. For example, in various non-limiting embodiments, core layer 102 is configured to extend beyond the total thickness of clad composite 100 (i.e., t total ) of the total thickness (t total 2, in various non-limiting embodiments, the second layer 106, when present, may include a second thickness t2 that is within the range of 3% to 20% of the total thickness (t total ) of the clad composite 100, 200. In various non-limiting embodiments, the first thickness t1 is greater than the second thickness t2 and greater than the third thickness t3. In certain non-limiting embodiments, with reference to FIGS. 1-2, the total thickness (t total ) is in the range of 100 μm to 5 mm, for example in the range of 200 μm to 1 mm.

[0030] 4 is a block diagram of a non-limiting embodiment of a method according to the present disclosure for forming a clad composite according to the present disclosure and an article, such as, for example, a heat exchanger, including the clad composite. In certain non-limiting embodiments, the method includes forming a clad composite, such as clad composite 100, 200 (FIG. 4, step 402). For example, non-limiting embodiments of the method can include casting the core layer 102, the first layer 104, and optionally the second layer 106 using a multi-layer casting process, hot working (e.g., hot rolling) an assembly including a sheet of core layer 102, a sheet of first layer 104, and optionally a sheet of second layer 106 to combine the layers and form clad composite 100, 200, or a combination of multi-layer casting and hot working.

[0031] Referring again to FIG. 4 , the method further includes, after formation of the clad composite (e.g., clad composites 100, 200), contacting the first portion including the first material with a second portion including all or a portion of a non-limiting embodiment of the clad composite ( FIG. 4 , step 404). For example, non-limiting embodiments of methods according to the present disclosure may include contacting the first portion including the first material with a second portion including all or a portion of the clad composite 100, 200. In various non-limiting embodiments, the first portion can be bonded to the second portion ( FIG. 4 , step 406). For example, the first portion can be bonded to the second portion by adhesive, welding, soldering, brazing, mechanical bonding, or a combination thereof. In various non-limiting embodiments, the first material includes aluminum or an aluminum alloy, such as a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

[0032] In various non-limiting embodiments according to the present disclosure, a clad composite (e.g., clad composite 100, 200) can have a composition and thickness suitable for forming into a tube. For example, with reference to FIG. 5 , clad composite 100 or clad composite 200 can be formed into tube 500. For example, clad composite 100 can be bent so that a first end 508 of clad composite 100 contacts a second end 510 of clad composite 100, thereby forming a tube. First end 508 and second end 510 can be joined together, for example, by adhesive, welding, soldering, brazing, or a combination thereof. The outer diameter d1 of the tube can be in a range of 3 millimeters (mm) to 30 mm, e.g., 3 mm to 8 mm, or 5 mm to 7 mm.

[0033] In various non-limiting embodiments, an article, such as a heat exchanger, can comprise a structural element that includes all or a portion of the clad composite 100, 200, e.g., all or a portion of the tube 500. The heat exchanger can have suitable galvanic corrosion resistance. The heat exchanger can be, for example, part of a heating, ventilation, and air conditioning (HVAC) system.

[0034] For example, referring to FIG. 6 , the tubes 500 can be part of a heat exchanger 600. As shown, the heat exchanger 600 includes tubes 500a-500d and fins 620a-620d. The fins 620a-620d can be arranged in stacks with gaps 622a-622b between each adjacent pair of fins 620a-620d. The widths of the gaps 622a-622b can be the same or different. In various non-limiting embodiments, the gaps 622a-622b can be absent, and adjacent fins can directly contact each other. The fins 620a-620d can have holes 624a-624d extending therethrough, which can receive the tubes 500a-500d. The tubes 500a-500d may be coupled to the fins 620a-620c by, for example, adhesives, welding, soldering, brazing, mechanical bonding (e.g., extending to a friction fit with the fins 620a-620c), or a combination thereof. The number of tubes 500a-500d, fins 620a-620d, and holes 624a-624d may vary based on the desired application. [Example]

[0035] The present disclosure will be more fully understood by reference to the following examples which describe certain non-limiting aspects of various embodiments according to the present disclosure.

[0036] Several aluminum alloy compositions were selected in accordance with the present disclosure, as listed below in Table 1. The corrosion potential of each listed aluminum alloy composition was estimated using an in-house developed computer model. [Table 1]

[0037] Several clad composites were modeled using aluminum alloy compositions A through G listed in Table 1. Several two-layer clad composites (Examples 1 through 10) were modeled to include a 100 μm thick first layer and a 600 μm thick core layer. A three-layer clad composite (Example 11) was modeled to include a 25 μm first layer, a 75 μm second layer, and a 600 μm core layer, with the second layer positioned intermediate the first and core layers. After the selected layers were virtually assembled, a brazing diffusion computer model was applied to the assembly to virtually bond the layers together to form a virtual clad composite, and the corrosion potential was modeled across the thickness of the clad composite. The corrosion potential calculated across the thickness of the clad composite was used to evaluate the expected corrosion performance of the composite. The results are shown in Table 2 below. [Table 2]

[0038] Based on evaluation using computer models, good corrosion performance of the clad composite was predicted when the difference in corrosion potential between the first layer and the core layer was at least 8 mV, as shown in Table 2. Other embodiments of clad composites according to the present disclosure are also expected to exhibit good corrosion performance.

[0039] The following numbered sections are directed to various non-limiting embodiments and aspects according to the present disclosure.

[0040] Item 1. Clad composite material, a core layer comprising a first aluminum alloy having a first corrosion potential; a first layer comprising a second aluminum alloy having a second corrosion potential; The clad composite has a second corrosion potential in the range of -600 mV to -800 mV, and the first corrosion potential is at least 8 mV and not more than 100 mV less electronegative than the second corrosion potential.

[0041] Item 2. The clad composite of item 1, wherein the first corrosion potential is less electronegative than the second corrosion potential by 50 mV or less.

[0042] Item 3. The clad composite material according to any one of Items 1 and 2, wherein the first corrosion potential is 30 mV or less less electronegative than the second corrosion potential.

[0043] Item 4. The clad composite material according to any one of Items 1 to 3, wherein the second corrosion potential is in the range of -700 mV to -730 mV, and the first corrosion potential is in the range of -650 mV to -720 mV.

[0044] Item 5. The clad composite material according to any one of Items 1 to 4, wherein the second corrosion potential is in the range of −715 mV to −730 mV, and the first corrosion potential is in the range of −690 mV to −720 mV.

[0045] Item 6. The clad composite material according to any one of Items 1 to 5, wherein the first layer is disposed on the core layer.

[0046] Section 7. a second layer intermediate the core layer and the first layer, the second layer comprising an aluminum alloy having a third corrosion potential; Item 7. The clad composite material according to any one of Items 1 to 6, wherein the third corrosion potential is lower than the first corrosion potential and higher than the second corrosion potential.

[0047] Section 8. the core layer includes a first concentration of a first cathode material; Item 8. The clad composite of any one of items 1 to 7, wherein the first layer includes a second concentration of the second cathode material, the first concentration being greater than the second concentration.

[0048] Item 9. The clad composite of Item 8, wherein the first cathode material and the second cathode material each comprise a material independently selected from the group consisting of Cu, Zn, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, Li, and combinations of two or more thereof.

[0049] Item 10. The clad composite according to Item 9, wherein the first cathode material and the second cathode material are Cu.

[0050] Item 11. The clad composite of item 10, wherein the first concentration is at least 0.1 weight percent greater than the second concentration.

[0051] Item 12. The clad composite according to any one of Items 8 to 10, wherein the core layer contains at least 0.5 weight percent of the first cathode material.

[0052] Section 13. the core layer contains Cu in a weight percent range of 0.5 to 1.0; Item 13. The clad composite material according to any one of items 1 to 12, wherein the first layer contains 0.25 to 0.5 weight percent Cu.

[0053] Item 14. The clad composite material according to any one of Items 1 to 13, wherein the core layer and the first layer are bonded to each other.

[0054] Item 15. The clad composite according to any one of Items 1 to 14, wherein the second aluminum alloy contains, in weight percent, 0.05 to 1.0 Si, 0.25 to 0.5 Cu, 0 to 0.5 Zr, 0 to 0.8 Fe, 0.1 to 1.5 Mn, 0 to 0.25 Zn, 0 to 0.2 Mg, 0 to 0.2 Ti, 0 to 1 Cr, 0 to 0.5 Bi, aluminum, optionally one or more accessory elements, and impurities.

[0055] Item 16. The clad composite according to any one of Items 1 to 15, wherein the first aluminum alloy contains, in weight percent, 0.05 to 1.5 Si, 0 to 0.8 Fe, 0.5 to 1.0 Cu, 0.5 to 1.8 Mn, 0 to 0.2 Mg, 0 to 0.25 Zn, 0 to 0.25 Cr, 0 to 0.15 Zr, aluminum, optionally one or more accessory elements, and impurities.

[0056] Item 17. Goods, Item 17. The clad composite material according to any one of items 1 to 16, a fin bonded to a first layer of clad composite, the fin comprising a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

[0057] Item 18. The article according to Item 17, wherein the fins have a corrosion potential in the range of -740 mV to -900 mV.

[0058] Item 19. The article according to any one of Items 17 to 18, wherein the clad composite material is in a tubular shape.

[0059] Item 20. The article according to any one of Items 17 to 19, wherein the fin contains Zn in a weight percent of 0.25 or less.

[0060] Item 21. A heat exchanger comprising a structural element including all or a portion of the article according to any one of items 17 to 20.

[0061] Item 22. The heat exchanger of item 21, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

[0062] Item 23. A method for forming an article, comprising: Contacting a first portion including a first material with a second portion including all or a portion of the clad composite material according to any one of items 1 to 22; and binding the first moiety to the second moiety.

[0063] Item 24. The method of item 23, wherein the first material comprises a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

[0064] Item 25. The method according to any one of Items 23 to 24, wherein the article is a heat exchanger.

[0065] Clause 26. The method of clause 25, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

[0066] As used herein, unless otherwise indicated, all numerical parameters should be understood to be prefaced and modified in all instances by the term "about," given the inherent variability characteristic of the underlying measurement technique used to determine the numerical value of that parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter set forth herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0067] Additionally, any numerical range recited herein includes all subranges subsumed within the recited range. For example, a range "1 to 10" includes all subranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, i.e., having a minimum value of 1 or greater and a maximum value of 10 or less. Also, all ranges recited herein include the endpoints of the recited range. For example, a range "1 to 10" includes the endpoints 1 and 10. Any maximum numerical limitation recited herein is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited herein is intended to include all higher numerical limitations subsumed therein. Accordingly, applicants reserve the right to amend this specification, including the claims, to explicitly recite any subranges subsumed within an explicitly recited range. All such ranges are inherently set forth herein.

[0068] As used herein, the grammatical articles "a," "an," and "the" are intended to include "at least one" or "one or more," unless otherwise indicated, even if "at least one" or "one or more" is expressly used in a particular instance. Accordingly, the foregoing grammatical articles are used herein to refer to one or more (i.e., "at least one") of the particular identified elements. Furthermore, the use of a singular noun includes the plural and the use of a plural noun includes the singular, unless the context of use requires otherwise.

[0069] Those skilled in the art will recognize that the articles and methods described herein, and the accompanying discussion, are used as examples for conceptual clarity, and that various structural modifications are contemplated. Accordingly, as used herein, the specific examples / embodiments described and the accompanying discussion are intended to be representative of their more general classes. In general, the use of a specific example is intended to be representative of its class, and the absence of specific components, devices, operations / acts, and objects should not be taken as limiting. While this disclosure provides descriptions of various specific embodiments for the purpose of illustrating various aspects of the disclosure and / or its potential applications, those skilled in the art will recognize that variations and modifications occur. Accordingly, the invention(s) described herein should be understood to be at least as broad as they are claimed, and not more narrowly defined by the specific illustrative embodiments provided herein.

Claims

1. A clad composite material comprising: a core layer comprising a first aluminum alloy having a first corrosion potential; a first layer comprising a second aluminum alloy having a second corrosion potential, the second aluminum alloy comprising 0 to 0.5 weight percent Zn; The clad composite material, wherein the second corrosion potential is in the range of −600 mV to −800 mV, and the first corrosion potential is at least 8 mV and no more than 100 mV less electronegative than the second corrosion potential.

2. The clad composite of claim 1 , wherein the first corrosion potential is no more than 50 mV less electronegative than the second corrosion potential.

3. The clad composite of claim 1 , wherein the first corrosion potential is no more than 30 mV less electronegative than the second corrosion potential.

4. The clad composite of claim 1, wherein the second corrosion potential is in the range of -700 mV to -730 mV and the first corrosion potential is in the range of -650 mV to -720 mV.

5. The clad composite of claim 1, wherein the second corrosion potential is in the range of -715 mV to -730 mV and the first corrosion potential is in the range of -690 mV to -720 mV.

6. The clad composite of claim 1 , wherein the first layer is disposed on the core layer.

7. a second layer intermediate the core layer and the first layer, the second layer comprising an aluminum alloy having a third corrosion potential; the third corrosion potential is lower than the first corrosion potential and higher than the second corrosion potential; The clad composite of claim 1 .

8. the core layer includes a first concentration of a first cathode material; the first layer includes a second concentration of a second cathode material; the first concentration is greater than the second concentration; The clad composite of claim 1 .

9. 9. The clad composite of claim 8, wherein the first cathode material and the second cathode material comprise materials individually selected from the group consisting of Cu, Zn, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, Li, and combinations of two or more thereof.

10. The clad composite of claim 9 , wherein the first cathode material and the second cathode material are Cu.

11. The clad composite of claim 10 , wherein the first concentration is at least 0.1 weight percent greater than the second concentration.

12. The clad composite of claim 8 , wherein the core layer comprises at least 0.5 weight percent of the first cathode material.

13. the core layer comprises 0.5 to 1.0 weight percent Cu; the first layer comprises 0.25 to 0.5 weight percent Cu; The clad composite of claim 1 .

14. The clad composite of claim 1 , wherein the core layer and the first layer are bonded to one another.

15. the second aluminum alloy comprising, in weight percent: 0.05 to 1.0 Si, 0.25 to 0.5 Cu, Zr of 0 to 0.5; Fe of 0 to 0.8; Mn of 0.1 to 1.5; Zn from 0 to 0.25; 0 to 0.2 Mg; Ti of 0 to 0.2; Cr between 0 and 1, Bi between 0 and 0.5, Aluminum and optionally one or more accessory elements; The clad composite of claim 1 , further comprising:

16. The first aluminum alloy comprises, in weight percent: 0.05 to 1.5 Si, Fe of 0 to 0.8; 0.5 to 1.0 Cu, Mn of 0.5 to 1.8; 0 to 0.2 Mg; Zn from 0 to 0.25; 0 to 0.25 Cr; Zr of 0 to 0.15; Aluminum and optionally one or more accessory elements; The clad composite of claim 1 , further comprising:

17. An article, The clad composite material of claim 1; a fin bonded to the first layer of the clad composite, wherein the fin comprises a 1xxx series aluminum alloy or a 3xxx series aluminum alloy.

18. 18. The article of claim 17, wherein the fin has a corrosion potential in the range of -740 mV to -900 mV.

19. The article of claim 17 , wherein the clad composite is in the shape of a tube.

20. 18. The article of claim 17, wherein the fin comprises Zn by weight percent equal to or less than 0.

25.

21. A heat exchanger comprising a structural element comprising all or a portion of the article of claim 17.

22. 22. The heat exchanger of claim 21, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

23. 1. A method for forming an article, comprising: contacting a first portion comprising a first material with a second portion comprising all or a portion of the clad composite of claim 1; and binding the first moiety to the second moiety.

24. 24. The method of claim 23, wherein the first material comprises a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

25. 24. The method of claim 23, wherein the article is a heat exchanger.

26. 26. The method of claim 25, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

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