High-strength aluminum alloy for food and beverage packaging and method for preparing the same

Abstract

This specification describes novel aluminum alloys, including recycled aluminum alloy materials exhibiting high strength and high formability. The aluminum alloys described herein are suitable for use in food and beverage packaging, such as can body components, and exhibit high strength and formability while having a higher Mg content than, for example, conventional 3xxx series aluminum alloys used in the manufacture of such packaging. This disclosure provides cost-effective alternatives to the use of AA3004 and AA3104 aluminum alloys for food and beverage packaging, which incorporate a larger amount of recycled scrap while having equivalent mechanical properties.

Description

Technical Field

[0001] Claim of Priority This application claims the priority of U.S. Provisional Application No. 63 / 579,771, filed on August 30, 2023, the entire content and disclosure of which are incorporated herein by reference.

[0002] This disclosure relates to the fields of metallurgy, aluminum alloys, aluminum fabrication, and related fields. In particular, the present disclosure provides novel aluminum alloys having a large amount of recycled aluminum material useful for manufacturing food and beverage packages including can body members.

Background Art

[0003] Can body members have conventionally been manufactured from high-strength aluminum alloys having good forming characteristics. The mechanical requirements for aluminum alloys used in manufacturing can body members are different from those for can end members. Generally, aluminum alloys for manufacturing can body members require lower strength than can end members. As a result, can body members are often manufactured from aluminum alloys having a lower magnesium (Mg) content than can end members. For example, the can body member may be manufactured from an AA3004 aluminum alloy having a Mg content between 0.80 wt% and 1.30 wt%.

[0004] Many aluminum manufacturers use 3xxx series aluminum alloys (e.g., AA3004 or AA3104) for can body components. However, recycled materials such as used beverage cans (UBCs) are not used to manufacture can end components and can body components because UBCs contain two distinct aluminum alloys with different aluminum alloy compositions. Specifically, can end components are typically made from AA5182 aluminum alloy, and can body components are typically made from AA3104 aluminum alloy. Because UBCs contain two different aluminum alloys, there is little commonality in the compositions for creating new aluminum alloys for can body components and can end components. Therefore, when using UBCs to manufacture new aluminum alloys, it is necessary to adjust the composition by adding primary aluminum and additional alloying elements to produce can end components and can body components. Thus, the addition of primary aluminum and / or additional alloying elements reduces the recyclability of recycled aluminum alloy products for manufacturing new aluminum alloys and decreases the recycled content. Furthermore, adding primary aluminum increases carbon dioxide production and raises costs, thus harming the environment and increasing costs. [Overview of the project]

[0005] The embodiments included in this disclosure are defined by the claims, not by the summary of the invention. The summary of the invention is a higher-level summary of various aspects of the invention and introduces some concepts that are further described in the sections on embodiments for carrying out the invention below. This summary is not intended to identify the main or important features of the claimed subject matter, nor is it intended to be used separately in determining the scope of the claimed subject matter. The subject matter should be understood by referring to the entire specification, any or all of the drawings, and the appropriate parts of each claim.

[0006] This specification describes an aluminum alloy that provides a more cost-effective and easily recyclable material compared to AA3004 and AA3104 alloys for use as packaging for food and beverages, including can body components. The aluminum alloy may contain up to 0.70 wt% Si, up to 0.80 wt% Fe, up to 0.60 wt% Cu, 0.80 to 1.50 wt% Mn, 1.30 to 2.00 wt% Mg, up to 0.60 wt% Zn, up to 0.30 wt% Cr, up to 0.10 wt% Ti, up to 0.15 wt% impurities, and Al, and the aluminum alloy contains at least 60 wt% recycled aluminum scrap. In some embodiments, the aluminum alloy contains 0.20–0.40 wt% Si, 0.40–0.60 wt% Fe, 0.10–0.30 wt% Cu, 0.80–1.00 wt% Mn, 1.35–1.50 wt% Mg, up to 0.25 wt% Zn, up to 0.05 wt% Cr, up to 0.05 wt% Ti, up to 0.15 wt% impurities, and Al, and the aluminum alloy may contain more than 75 wt% recycled aluminum scrap. The aluminum alloy may contain less than 15 wt% primary aluminum, or less than 5 wt% primary aluminum. The aluminum alloy may exhibit a yield strength of at least 200 MPa, preferably 200–350 MPa. The aluminum alloy may exhibit an ultimate tensile strength of at least 250 MPa, preferably 250–450 MPa. The aluminum alloy may contain up to 100 wt% recycled aluminum scrap. Recycled aluminum scrap may include used beverage can scrap. Used beverage can scrap may include a mixture of recycled metals from the can ends and can bodies.

[0007] In some embodiments, aluminum alloy products, such as can body members, can end members, can tab materials, and other food and beverage packaging, may include the aluminum alloys described herein.

[0008] In some embodiments, the aluminum alloy product may include casting an aluminum alloy to form a cast product, homogenizing the cast product, hot rolling the cast product to produce a hot-rolled product, cold rolling the hot-rolled product to produce an aluminum alloy product, and optionally annealing the aluminum alloy product. The aluminum alloy may be as described herein. The casting step may include continuous casting of the aluminum alloy to form a cast product. The casting step may include direct chill casting of the aluminum alloy to form a cast product. This method may further include lacquering and hardening the aluminum alloy product.

[0009] Further embodiments, purposes, and advantages will become apparent with reference to subsequent embodiments and drawings for carrying out the invention. [Brief explanation of the drawing]

[0010] [Figure 1] A flowchart illustrating a process for producing a high-strength, high-recycled-content aluminum alloy using UBC or other aluminum scrap, according to a particular aspect of this disclosure, is shown. [Figure 2] A flowchart illustrating a process for processing a final gauge-rolled aluminum product manufactured using a high-strength, high-recycled-content aluminum alloy, prior to downstream processing for can body component applications, according to a particular aspect of this disclosure. [Modes for carrying out the invention]

[0011] This specification describes novel aluminum alloys exhibiting high strength and formability for use in can body component applications. The aluminum alloys described herein exhibit high strength and formability while having a higher Mg content than conventional AA3004 and AA3104 aluminum alloys used to manufacture can body components. Compared to conventional AA6016 aluminum alloys used to manufacture can body components, the aluminum alloys described herein maintain the good mechanical properties of can body component aluminum alloys despite having a higher recycled aluminum content and a lower primary aluminum content. For example, the aluminum alloys described herein contain at least 60% recycled aluminum and less than 40% primary aluminum compared to conventional aluminum alloys used to manufacture can body components, yet can still exhibit similar mechanical properties to conventional 3xxx series aluminum alloys used for can body components. The aluminum alloy compositions described throughout this specification provide cost-effective alternatives to using AA3004 and AA3104 aluminum alloys in can body components.

[0012] In addition to its use in can body components, the novel aluminum alloy's high strength and formability, combined with its high Mg content, may also be useful in other applications. Such applications include any food and beverage packaging, including can body components, can tabs, can end components, food cans, and food can lids. The novel aluminum alloy can also be used in applications other than food and beverages, as long as high strength and formability are desirable.

[0013] While not bound by theory, the high formability of aluminum alloy products allows for more aggressive stretching and thinning processes, potentially yielding processing advantages. Furthermore, modifying the rolling process, such as using high speed and high temperature in a cold rolling mill, can improve variability in tensile strength and yield strength / ultimate tensile strength. This typically corresponds to improved product formability. Additionally, increasing the speed of the cold rolling mill during rolling can improve the recovery rate of the product from the cold rolling mill.

[0014] Conventional 3xxx series aluminum alloys used to manufacture can body components may require strictly controlled compositions to meet mechanical requirements (such as strength requirements) while still maintaining formability for manufacturing complex shapes. This limits the amount of recycled aluminum material that can be used to manufacture AA5182 aluminum alloy. For example, AA3104 aluminum alloy cannot be manufactured from large quantities of used beverage cans because it has a lower Mg content compared to used beverage cans. Used beverage cans contain a mixture of two different aluminum alloys in the can body and can end components. The aluminum alloy used for the can end components is typically AA5182 aluminum alloy, and the aluminum alloy used for the can body components is typically AA3104 aluminum alloy. Compared to AA5182 aluminum alloy, AA3104 aluminum alloy has a lower Mg content and higher Fe, Si, Mn, and Cu content. Due to the difference in aluminum alloy composition between AA3104 aluminum alloy and AA5182 aluminum alloy, used beverage cans have an aluminum alloy composition somewhere between AA3104 and AA5182. Therefore, in order to manufacture can body components from large quantities of recycled materials such as used beverage cans, it is necessary to manufacture AA3104 aluminum alloy (for example, by adding primary aluminum), taking into account the high Mg content of recycled aluminum scrap, which significantly increases manufacturing and environmental costs. This limits the amount of recycled aluminum alloy material that can be used to manufacture can body components.

[0015] The novel aluminum alloys described herein can utilize more recycled aluminum material and achieve properties equivalent to or exceeding those of AA3104 aluminum alloy. Specifically, the aluminum alloys described herein can tolerate a larger amount of Mg (e.g., 1.30% to 1.50% by weight) compared to conventional 3xxx series aluminum alloys for can body component applications, while still achieving good strength and formability. This can be particularly advantageous in relation to the key requirement of diluting the Mg content from scrap metal to a target level. Furthermore, using 3xxx series alloys instead of AA5182, particularly in can end component and can tab material applications, allows for a broader range of key elements. Such elements include Si, Fe, Cu, and Mn. As a result, this usage leads to a significant reduction in primary resource consumption and contributes to a substantial reduction in the carbon footprint.

[0016] Furthermore, the aluminum alloys described herein may contain a large amount of Mg, which can be compensated for by reducing elements such as Mn and Cu to compensate for Mg solid solution hardening. The composition of the aluminum alloys described herein reduces the composition gap between the can body and can end members, thereby reducing the amount of primary aluminum required. By reducing the composition gap between the aluminum alloys of the can body and can end members, it is possible to manufacture the aluminum alloy for the can body using more recycled aluminum alloy, such as used beverage cans. For example, the aluminum alloys described herein can be manufactured from at least 60% by weight of recycled scrap and less than 15% by weight of primary aluminum.

[0017] In addition to the improved sustainability of the aluminum alloys described herein, improved circularity may be achieved. Circularity refers to a production and consumption model aimed at reducing waste and optimizing resource use throughout the entire production and consumption cycle. Here, since aluminum alloys can be used in a variety of food and beverage applications, the carbon footprint of various manufacturing processes can be reduced. Furthermore, the aforementioned advantages of the recycled content, processing efficiency, and sustainability of this process each contribute to improved circularity compared to aluminum alloys with different compositions and manufacturing processes.

[0018] Furthermore, the aluminum alloy composition can produce can body components with properties similar to conventional AA3004 or AA3104 aluminum alloys, allowing can manufacturers to produce the aluminum alloy with little to no modification to existing methods. Due to the high Mg content of the aluminum alloy, the composition can increase sheet strength while maintaining good buckling strength, while preserving formability and tear performance. Conventional strengthening approaches (e.g., addition of Mn, addition of Cu, or increasing the thickness of hot-rolled sheets) may have negative side effects (e.g., increased particle content, loss of formability, loss of productivity). In contrast, the addition of Mg can increase ductility while maintaining particle content and particle size, and when properly controlled. In some embodiments, a large quantity of used beverage cans can be used in the aluminum alloy described herein, thereby reducing the amount of primary aluminum required, lowering the total cost, and maintaining equivalent or better rolling productivity. In addition to the high strength mainly obtained from the relatively increased Mg and Mn content, the high strength also advantageously allows for increased weight reduction (potential downgauge).

[0019] The aforementioned aluminum alloy compositions offer processing advantages despite their high proportion of recycled aluminum alloy, a common problem when using large amounts of recycled aluminum alloy in new aluminum alloys. The aluminum alloys described herein can be reused to manufacture other aluminum alloy products (e.g., can body components). Beneficially, the incorporation of a large amount of Mg enables closed-loop recycling of used beverage cans (UBCs) manufactured from the aluminum alloy compositions described herein. Thus, UBC scrap can be continuously reused in a closed-loop system to manufacture aluminum alloys without significantly altering the alloying elements. That is, aluminum alloy products (e.g., UBCs) made from the aluminum alloy compositions described herein can be used to manufacture new aluminum alloys for can end components or can body components. Furthermore, through careful adjustment of the alloy design and elemental control, the Mg content in UBC scrap is similar to that of the aluminum alloy compositions described herein. Surprisingly, aluminum alloys can be manufactured from UBCs to produce can body components while containing up to 100% by weight of recycled aluminum scrap. Another advantage of this processing method is that while strength naturally increases with the addition of Mg, the cold rolling mill outlet temperature can rise without losing strength. This indicates that the cold rolling mill speed can be accelerated, improving the productivity of the cold rolling mill.

[0020] In some embodiments, this disclosure relates to aluminum alloys having a high Mg content and a high recycled content, exhibiting properties similar to AA3004 and AA3104 aluminum alloys. For example, the aluminum alloys may contain Mg content equal to or greater than that of AA3004 and AA3104 aluminum alloys. The aluminum alloys may contain a high amount of recycled material and achieve properties similar to those of AA3104 aluminum alloys. In some embodiments, the aluminum alloys described herein may contain Mg content from 1.30% to 2.00% by weight. UBC scrap can be used almost entirely to produce the aluminum alloys, thereby eliminating the need to dilute the aluminum alloy with primary aluminum or add alloying elements for hardening. In other words, the prepared aluminum alloys described herein may contain a large amount of UBC scrap and a small amount of primary aluminum, with minimal or no additional alloying elements. Advantageously, the aluminum alloys may contain Cu, Mn, and Mg to meet the strength requirements of can body members. The aluminum alloys described herein may contain more Mg than AA3104 aluminum alloy while meeting the minimum strength requirements for can body members, and may contain Mg between 1.30% and 2.00% by weight. In some embodiments, can end members may be formed from the alloys described herein, but conventional alloys such as A5182 may be used to form the can body members and can tab members.

[0021] To maintain a high recycled content in the aluminum alloy compositions described herein, the aluminum alloy composition may be similar to that of AA3104 aluminum alloy, although the Cu and Mn content is reduced. Therefore, it may not be necessary to add other hardening alloying elements (e.g., Mn and Cu) to the aluminum alloy composition. This is beneficial because the hardening alloying elements (e.g., Mn and Cu) do not oxidize during the remelting process and do not affect the recyclability of the aluminum alloy or UBC composition of the can body. Maintaining an aluminum alloy composition similar to that of AA3104 aluminum alloy simplifies the remelting process, thereby reducing the need to alter the aluminum alloy during manufacturing. The aluminum alloy compositions described herein have a high recycled content and low primary aluminum content, while also exhibiting mechanical properties similar to current aluminum alloy compositions for can body components (e.g., similar to AA3004 aluminum alloy or AA3104 aluminum alloy).

[0022] Definition and Description As used herein, the terms “invention,” “the invention,” “this invention,” and “this present invention” are intended to broadly refer to the subject matter of this patent application and all of the claims below. It should be understood that any phrasing containing these terms is not intended to limit the subject matter described herein, nor to limit the meaning or scope of the claims below.

[0023] In this description, reference is made to alloys identified by the names of the aluminum industry such as "series" or "3xxx series". For an understanding of the numbering systems most commonly used for the naming and identification of aluminum and its alloys, reference should be made to either "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot", both of which are issued by the Aluminum Association.

[0024] As used herein, the meanings of "a", "an", or "the" include references to the singular and plural unless the context clearly dictates otherwise.

[0025] As used herein, plates generally have a thickness greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0026] As used herein, sheets (also called sheet plates) generally have a thickness of from about 4 mm to about 15 mm. For example, a sheet may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0027] As used herein, a sheet refers to an aluminum casting having a thickness of less than about 4 mm (e.g., less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm). For example, the sheet can have a thickness of about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, or about 4 mm.

[0028] As used herein, formability refers to the ability of a material to deform into a desired shape without the occurrence of forming errors such as cracking, tearing, necking, ear formation, or wrinkles, springback, or nibbling. In engineering, formability can be classified by deformation mode. Examples of deformation modes include drawing, stretching, bending, stretch flanging, etc.

[0029] As used herein, primary aluminum refers to an aluminum material containing at least about 99.7 wt% aluminum. Primary aluminum is produced from the primary transformation of raw material aluminum (e.g., the processing of bauxite to alumina and the electrolysis of alumina to aluminum).

[0030] As used herein, the yield stress (also called yield strength) refers to the point at which an aluminum alloy begins to plastically deform and cannot return to its original state.

[0031] In this application, the temper or state of the alloy may be referred to. To understand the most commonly used descriptions of alloy temper, please refer to "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems". F temper or temper refers to aluminum alloy in the as-made state. O state or temper refers to aluminum alloy after annealing. Hxx state or temper, also referred to herein as H temper, refers to aluminum alloy that is not heat-treatable after cold rolling, with or without heat treatment (e.g., annealing). Preferred H tempers include HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8, or HX9 tempers. T1 state or temper refers to aluminum alloy that has been cooled from hot working and naturally aged (e.g., at room temperature). T2 state or temper refers to aluminum alloy that has been cooled from hot working, cold working, and naturally aged. T3 state or temper refers to aluminum alloy that has been solution-treated, cold-worked, and naturally aged. T4 state or temper refers to aluminum alloy that has been solution-treated and naturally aged. T5 state or temper refers to aluminum alloy that has been cooled from hot-worked and artificially aged (by heating). T6 state or temper refers to aluminum alloy that has been solution-treated and artificially aged. T7 state or temper refers to aluminum alloy that has been solution-treated and artificially overaged. T8x state or temper refers to aluminum alloy that has been solution-treated, cold-worked, and artificially aged. T9 state or temper refers to aluminum alloy that has been solution-treated, artificially aged, and cold-worked. W state or temper refers to aluminum alloy after solution treatment.

[0032] As used herein, “room temperature” means a temperature between approximately 15°C and approximately 30°C, for example, approximately 15°C, approximately 16°C, approximately 17°C, approximately 18°C, approximately 19°C, approximately 20°C, approximately 21°C, approximately 22°C, approximately 23°C, approximately 24°C, approximately 25°C, approximately 26°C, approximately 27°C, approximately 28°C, approximately 29°C, or approximately 30°C.

[0033] All disclosures herein should be understood to encompass both endpoints and any subranges contained therein. For example, a range described as "1 to 10" should be considered to include any and all subranges (including 1 and 10) between a minimum value of 1 and a maximum value of 10. That is, all subranges begin with a minimum value of 1 or greater, e.g., 1 to 6.1, and end with a maximum value of 10 or less, e.g., 5.5 to 10.

[0034] The following aluminum alloys are described in terms of their elemental composition in weight percentage (wt%) based on the total weight of the alloy. In specific examples of each alloy, the remainder is aluminum, and the maximum wt% of the total impurities is 0.15%.

[0035] Alloy composition The properties of an aluminum alloy are determined, at least in part, by its composition. In certain embodiments, the alloy composition can influence, or even determine, whether the alloy has properties suitable for a desired application.

[0036] The alloys described herein are novel aluminum alloys. These alloys exhibit high strength and high formability (e.g., elongation and formability suitable for can body component applications) and contain a higher proportion of recycled aluminum alloys. The properties of the alloys are achieved, at least in part, due to the elemental compositional properties of the alloys. In some cases, the novel aluminum alloys described herein may contain higher Mg content and the same levels of Si and Fe compared to conventional AA3104 aluminum alloys, as will be further described below.

[0037] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 1. [Table 1]

[0038] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 2. [Table 2]

[0039] Silicon (Si) In some examples, the aluminum alloys described herein contain Si in amounts up to 0.70% (e.g., 0.20% to 0.40%, up to 0.20%, up to 0.40%, up to 0.60%) based on the total weight of the alloy. For example, alloys are 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0 It may contain 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, or 0.70% Si. All are expressed in wt%.

[0040] Iron (Fe) In some examples, the aluminum alloys described herein also contain Fe in amounts up to 0.80% (e.g., 0.40% to 0.60%, up to 0.20%, up to 0.40%, up to 0.60%) based on the total weight of the alloy. For example, the alloys contain Fe in amounts of 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0. 20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0 It may contain 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, or 0.80% Fe. All values ​​are expressed in wt%. In some embodiments, aluminum alloy compositions containing less than 0.20 wt% Fe may result in processing defects. For example, aluminum alloys may have poor runout due to excessive mold buildup. Runout refers to whether the aluminum alloy contains defects or interferences during the manufacturing process of the aluminum alloy. Furthermore, the inclusion of less than 0.20 wt% Fe in the aluminum alloy composition may limit the amount of recycled aluminum alloy material that can be used in the aluminum alloy.

[0041] Copper (Cu) In some examples, the aluminum alloys described herein contain Cu in amounts up to 0.60% (e.g., 0.10% to 0.30%, up to 0.20%, up to 0.40%) based on the total weight of the alloy. For example, the alloys may contain 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0. It may contain 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, or 0.60% Cu. All are expressed in wt%.

[0042] Manganese (Mn) In some examples, the aluminum alloys described herein may contain Mn in amounts of 0.80% to 1.50% (e.g., 0.80% to 1.40%, 0.85% to 1.30%, 0.90% to 1.20%, or 0.95% to 1.25%, 0.80% to 1.00%) based on the total weight of the alloy. For example, alloys are 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.00%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15% Mn may include %, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, or 1.50%. All are expressed in wt%.

[0043] Magnesium (Mg) In some examples, the aluminum alloys described herein may contain Mg in amounts of 1.30% to 2.00% (e.g., 1.35% to 1.50%, 1.40% to 1.70%, 1.30% to 1.65%, or 1.35% to 1.90%) based on the total weight of the alloy. For example, alloys are 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, 1.50%, 1.51%, 1.52%, 1.53%, 1.54%, 1.55%, 1.56%, 1.57%, 1.58%, 1.59%, 1.60%, 1.61%, 1.62%, 1.63%, 1.64%, 1.65%, 1 It can contain 0.66%, 1.67%, 1.68%, 1.69%, 1.70%, 1.71%, 1.72%, 1.73%, 1.74%, 1.75%, 1.76%, 1.77%, 1.78%, 1.79%, 1.80%, 1.81%, 1.82%, 1.83%, 1.84%, 1.85%, 1.86%, 1.87%, 1.88%, 1.89%, 1.90%, 1.91%, 1.92%, 1.93%, 1.94%, 1.95%, 1.96%, 1.97%, 1.98%, 1.99%, or 2.00% Mg. All are expressed in wt%.

[0044] In some cases, the novel aluminum alloys described herein may contain a higher Mg content (e.g., 0.80% to 1.30% by weight) than conventional 3xxx series aluminum alloys for can body component applications. For example, a novel aluminum alloy may contain 54% more Mg than conventional 3xxx series aluminum alloys for can body component applications. Furthermore, the novel aluminum alloys described herein may contain less of one or more Cu or Mn compared to conventional 3xxx series aluminum alloys. For example, an aluminum alloy may contain lower amounts of Cu or Mn to compensate for the increased Mg content in the novel aluminum alloys described herein. By reducing the Cu and Mn content, Mg solid solution hardening can be compensated for, enabling improved can manufacturing performance. Because the Mg content is increased and the Cu and Mn content is decreased, manufacturing the novel aluminum alloys avoids the need to add additional alloying elements (e.g., Mg, Cu, Mn, etc.) to the aluminum alloy composition, thus reducing costs.

[0045] Chromium (Cr) In some examples, the aluminum alloys described herein contain Cr in amounts up to 0.30% (e.g., up to 0.20%, up to 0.10%, up to 0.05%, up to 0.03%, 0.05% to 0.10%, or 0.06% to 0.10%) based on the total weight of the alloy. For example, the alloys may contain 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, It may contain 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, or 0.30% Cr. In some cases, Cr is not present in the alloy (i.e., 0%). All values ​​are expressed in wt%.

[0046] Zinc (Zn) In some examples, the aluminum alloys described herein contain Zn in amounts up to 0.60% (e.g., up to 0.20%, up to 0.25%, up to 0.30%, up to 40%, up to 50%, 0.10% to 0.40%, 0.15% to 0.35%, or 0.20% to 0.30%) based on the total weight of the alloy. For example, alloys are 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0 It may contain Zn in the following proportions: 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, or 0.60%. In some cases, Zn is not present in the alloy (i.e., 0%). All proportions are expressed in wt%.

[0047] Titanium (Ti) In some examples, the aluminum alloys described herein contain Ti in amounts up to 0.10% (e.g., up to 0.05%, up to 0.03%, 0.05% to 0.10%, or 0.06% to 0.10%) based on the total weight of the alloy. For example, an alloy may contain 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20% Ti. In some cases, Ti may not be present in the alloy (i.e., 0%). All values ​​are expressed in wt%.

[0048] trace elements Optionally, the aluminum alloys described herein may further contain other trace elements, sometimes referred to as impurities, in amounts of 0.05%, 0.04%, 0.03%, 0.02%, or 0.01% or less. These impurities may include, but are not limited to, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Therefore, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be present in the alloy in amounts of 0.05%, 0.04%, 0.03%, 0.02%, or 0.01% or less. The total amount of all impurities shall not exceed 0.15% (e.g., 0.10%). All amounts are expressed in wt%. The remaining proportion of each alloy may be aluminum.

[0049] recycled content The aluminum alloys described herein can exhibit desirable mechanical properties despite allowing for larger amounts of recycled aluminum alloy scrap. The influence of impurities and / or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing an aluminum alloy composition adjusted to compensate for the impurities. This makes it possible to use larger amounts of cheaper, more impurity-laden recycled aluminum material (e.g., used beverage cans) to produce aluminum alloys that can exhibit desirable properties. The aluminum alloy compositions described herein may contain larger amounts of recycled aluminum alloy (e.g., at least 60% by weight) that contain little to no additional primary aluminum and little to no additional alloying elements (e.g., Cu or Mn).

[0050] In some embodiments, the aluminum alloy compositions described herein provide compositions suitable for utilizing used beverage can (UBC) scrap or other aluminum alloy containers as recycled materials. UBC scrap is a mixture of various aluminum alloys (e.g., from different aluminum alloys used for the can body and can end) and may often contain impurities such as rainwater, leftover beverages, organic matter, and other materials (e.g., paints and laminate films). UBC scrap typically contains a mixture of metals from various aluminum alloys, e.g., metals from the can body (e.g., AA3104, AA3004, or other 3xxx series aluminum alloys) and metals from the can end (e.g., AA5182 or other 5xxx series aluminum alloys). UBC scrap may be cut, decoated, or depainted before being melted down for use as a liquid metal stock in the casting of new metal products.

[0051] As discussed herein, the aluminum alloy compositions described herein reduce the composition gap between the can body members and the can end members, and between the can end members and the can tab material (both of which may be made from AA5192 alloy). This allows for the use of more recycled aluminum alloy, particularly UBC scrap, to manufacture the can body members, reducing the amounts of both primary aluminum and additional alloying elements (e.g., Cu or Mn). In some embodiments, the aluminum alloys described herein contain a large amount of recycled aluminum scrap, more than 60% (e.g., more than 65%, more than 70%, more than 75%, more than 80%, more than 85%, more than 90%, more than 95%, or 100%). In terms of range, the aluminum alloys described herein may contain 60% to 100% UBC scrap (e.g., more than 65% to 95%, more than 60% to 90%, more than 65% to 85%, more than 60% to 80%, more than 70% to 100%, or more than 75% to 90%). All percentages are expressed in wt%.

[0052] As described above, in some embodiments, UBC scrap includes a mixture of alloys, including 3xxx series aluminum alloys and 5xxx series aluminum alloys. In some embodiments, UBC scrap may contain 0% to 75% (e.g., 5% to 70%, 10% to 65%, 15% to 60%, 20% to 50%, or 25% to 40%) of 5xxx series aluminum alloys, based on the total weight of the recycled scrap. For example, UBC scrap may contain more than 0% (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) of 5xxx series aluminum alloy scrap, based on the total weight of the UBC scrap. All are expressed in wt%.

[0053] In some embodiments, UBC scrap may contain 0% to 75% (e.g., 5% to 70%, 10% to 65%, 15% to 60%, 20% to 50%, or 25% to 40%) of 3xxx series aluminum alloy scrap (derived from mixed alloy scrap) based on the total weight of the UBC scrap. For example, UBC scrap may contain more than 0% (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) of 3xxx series aluminum alloy scrap based on the total weight of the UBC scrap. All are expressed in wt%.

[0054] In some embodiments, the aluminum alloys described herein contain less than 15% primary aluminum (e.g., less than 14%, less than 13%, less than 12%, less than 11%, less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4%, less than 3%, less than 2%, or less than 1%). All are expressed in wt%. In some cases, the aluminum alloys described herein may not contain primary aluminum.

[0055] characteristics In some cases, aluminum alloy products manufactured from the aluminum alloys described herein (e.g., aluminum alloy sheets) may have a yield strength of about 200 MPa or more. In some cases, the yield strength may be between about 200 MPa and about 350 MPa, or any value in between. The aluminum alloy products described herein may exhibit the yield strengths described herein when measured in the longitudinal (L), transverse (T), and / or diagonal (D) directions with respect to the rolling direction, respectively.

[0056] In some cases, aluminum alloy products manufactured from the aluminum alloys described herein may have an ultimate tensile strength of about 250 MPa or more. In some cases, the ultimate tensile strength is between about 250 MPa and about 450 MPa, or any value in between. The aluminum alloy products described herein may exhibit the ultimate tensile strengths described herein when measured in the longitudinal (L), transverse (T), and / or oblique (D) directions with respect to the rolling direction, respectively.

[0057] Manufacturing method for aluminum alloys Figure 1 shows a flowchart illustrating a process 100 for producing an aluminum alloy from recycled aluminum scrap according to a particular aspect of the present disclosure. In block 102, recycled aluminum scrap (e.g., UBC scrap) is melted. The scrap may be melted in any suitable container (e.g., a rotary furnace, a crucible furnace, etc.). The liquid metal obtained by melting the recycled aluminum scrap may contain an amount of alloying elements that makes the liquid metal a non-standard alloy, such as alloys not conventionally used for beverage components (e.g., can end pieces or can bodies). For example, if the recycled aluminum scrap is UBC scrap, the liquid metal may include a combination of 3xxx series aluminum alloys conventionally used to manufacture can body components and 5xxx series aluminum alloys conventionally used to manufacture can end pieces.

[0058] In block 104, additional alloying elements can be optionally added to the liquid metal to produce a modified liquid metal containing appropriate amounts of alloying elements. Adding alloying elements may involve melting raw elements or mixtures of aluminum and alloying elements into the liquid metal from block 102. In additional or alternative embodiments, primary aluminum can be added to the liquid metal to dilute certain alloying elements.

[0059] The modified liquid metal from block 104 may be cast to produce a cast product 114. In some cases, if no additional alloying elements or primary aluminum are added to the liquid metal of block 102, the liquid metal of block 102 may be cast directly to produce the cast product 114. The aluminum alloys described herein may be cast into a casting 114 using a direct chill (DC) process, or optionally using a continuous casting (CC) process. The casting process is carried out according to standards widely used in the aluminum industry as known to those skilled in the art. In block 106, a cast product 114 can be produced using a DC casting apparatus. The DC casting process may form a cast product (e.g., an ingot). Optionally, instead of using a DC casting device, the modified liquid metal from block 104 may be cast in block 107 using a CC device, as described with reference to block 106, to produce a cast product 114. The CC process may include, but is not limited to, the use of a twin-belt casting machine, a twin-roll casting machine, or a block casting machine. In some cases, the casting process is carried out by a CC process for forming slabs, strips, etc. The cast product 114 obtained from block 106 or block 107 may contain less than 15% by weight of primary aluminum (e.g., less than 14% by weight, less than 13% by weight, less than 12% by weight, less than 11% by weight, less than 10% by weight, less than 9% by weight, less than 8% by weight, less than 7% by weight, less than 6% by weight, less than 5% by weight, less than 4% by weight, less than 3% by weight, less than 2% by weight, or less than 1% by weight of primary aluminum).

[0060] The cast product may then be subjected to further processing steps. Optionally, further processing steps may be used to prepare aluminum alloy products (e.g., sheets, shades, or plates). Such processing steps include, but are not limited to, homogenization steps, hot rolling steps, cold rolling steps, and optional lacquering steps. Other optional processing steps may include degreasing or lubrication steps. Processing steps related to castings are described below. However, the processing steps may also be used for cast slabs or strips using modifications known to those skilled in the art.

[0061] homogenization In block 108, the casting 114 of block 106 may be heated during the homogenization step to a homogenization temperature, for example, in the range of about 400°C to about 600°C. For example, the casting 114 may be heated to temperatures of 400°C, 410°C, 420°C, 430°C, 440°C, 450°C, 460°C, 470°C, 480°C, 490°C, 500°C, 510°C, 520°C, 530°C, 540°C, 550°C, 560°C, 570°C, 580°C, 590°C, or 600°C. In some embodiments, the heating rate to the peak metal temperature may be about 70°C / hour or less, about 60°C / hour or less, or about 50°C / hour or less. The casting 114 may then be soaked for a period of time (i.e., held at the indicated temperature) to form the homogenized product 116. In some examples, the total time for the homogenization steps, including the heating and immersion stages, can be up to approximately 10 hours (for example, up to 9 hours, up to 8 hours, up to 7 hours, up to 6 hours, up to 5 hours, up to 4 hours, up to 3 hours, up to 2 hours, or up to 1 hour).

[0062] Hot rolling Following the homogenization step, a hot rolling step may be carried out in block 110. In certain embodiments, the homogenized product 116 can be hot-rolled using a rolling mill to produce a hot-rolled product 118 having an intermediate gauge. In additional or alternative embodiments, the cast product 114 of block 107 can be hot-rolled in block 110 to produce a hot-rolled product 118. The hot rolling step may include a hot inversion mill operation or a hot tandem mill operation. Before the start of hot rolling, the homogenized product 116 can be cooled to a desired temperature (e.g., about 200°C to about 425°C). For example, the homogenized product 116 can be cooled to a temperature of about 200°C to about 400°C, about 250°C to about 375°C, about 300°C to about 425°C, or about 350°C to about 400°C. The homogenized product 116 can then be hot-rolled at a hot-rolling temperature of approximately 200°C to 550°C to produce a hot-rolled product 118 (e.g., a hot-rolled plate, a hot-rolled shade, or a hot-rolled sheet). For example, the hot-rolling step can be carried out at a hot-rolling temperature of approximately 250°C to 300°C, approximately 300°C to 500°C, or approximately 350°C to 450°C.

[0063] cold rolling In block 112, the hot-rolled product 118 can be cold-rolled using a cold-rolling mill to become a thinner aluminum alloy product such as the final gauge-rolled product 120. In certain embodiments, the cold-rolling step reduces the thickness of the hot-rolled product 118 by at least 80% (e.g., at least 90%, at least 95%, or about 85% to about 95%). For example, the cold-rolling step reduces the thickness of the hot-rolled product 118 by about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, or about 95%. The final gauge-rolled product 120 may have a gauge between approximately 0.20 and approximately 0.35 mm (e.g., approximately 0.20 to approximately 0.30 mm) or between approximately 0.008 and approximately 0.013 inches. Optionally, the final gauge-rolled product 120 may have a gauge of approximately 0.20 mm, approximately 0.21 mm, approximately 0.22 mm, approximately 0.23 mm, approximately 0.24 mm, approximately 0.25 mm, approximately 0.26 mm, approximately 0.27 mm, 0.28 mm, approximately 0.29 mm, approximately 0.30 mm, approximately 0.31 mm, approximately 0.32 mm, approximately 0.33 mm, approximately 0.34 mm, or approximately 0.35 mm. In some embodiments, the cold rolling step may include one or more cold rolling steps to achieve the desired gauge thickness reduction. Optionally, the process for producing an aluminum alloy may include an annealing step during or after the cold rolling step (for example, between one or more cold rolling steps).

[0064] Degreasing Several optional steps may be performed following the cold rolling step. Figure 2 is a flowchart of a process 200 for processing a final gauge-rolled product 120 manufactured using a high-strength, high-recycled-content aluminum alloy before downstream processing for can body component applications, according to a particular aspect of this disclosure. For example, process 200 may optionally include at least one deformation step applied to the final gauge-rolled product 120 in block 202. As used herein, the term “degreasing” includes processing the final gauge-rolled product 120 to remove residual oil accumulated on the surface during the hot-rolling and cold-rolling processes. The degreasing step may also remove residual surface debris, rolling oil, and aluminum fines from the rolling process. The degreasing surface improves the surface appearance of the final gauge-rolled product 120 and reduces the accumulation of aluminum fines during downstream processing, for example, during the cupping step for manufacturing can body components. The degreasing agent used in the degreasing step may include water and / or solvents. Optionally, the water used for the degreasing step may be hot water (i.e., water with a temperature of at least about 35°C, e.g., about 35°C to about 100°C). In some cases, the degreasing agent may contain an acidic or alkaline agent. For example, suitable acidic agents for use in the degreasing step include phosphoric acid, sulfuric acid, hydrochloric acid, or mixtures thereof. In some cases, the degreasing agent may contain a wetting agent. Optionally, the degreasing agent may be used in combination with electrochemical cleaning. In some cases, the level of degreasing is controlled by the concentration of the agent in the degreasing section, the current density, the degreasing time, and / or the temperature. After degreasing and before lubrication, the final gauge-rolled product 120 may be rinsed with water and dried. In some embodiments, a post-annealing process may be applied. For example, the post-annealing process may include immersion at a temperature of 150°C to 250°C for up to 5 hours.

[0065] Lubrication As another example, after the cold rolling step, the final gauge-rolled product 120 may optionally be subjected to a lubrication step of block 204. The processes described herein may optionally include at least one lubrication step applied to the aluminum alloy product. As used herein, the term “lubrication” includes treating the aluminum alloy product to apply a lubricant for subsequent cupping production. Optionally, the lubricant applied may be a dry-film lubricant. In some cases, the lubricant may be applied uniformly. In some cases, the lubrication step eliminates the need for the use of additional lubricants during downstream processing (e.g., during the cupping step).

[0066] Instructions for use and downstream processing The aluminum alloy products and methods described herein can be used in the manufacture of beverage cans, food containers, or any other desired applications. In some examples, the aluminum alloy products and methods can be used to prepare can bodies. The aluminum alloy products described herein may be used in downstream processes such as a cupping process in block 208. The cupping process may include cutting a circular disc of the final gauge-rolled product 120 and forming the circular disc into a cup, which can be further processed into a beverage can body. Beverage cans prepared using the beverage can body may have filling capacities or can sizes of 8.4 oz, 12 oz standard (e.g., height approximately 122.22 mm), 12 oz sleek (e.g., height approximately 156.59 mm), 16 oz, 19.2 oz, 24 oz, 222 mL, 250 mL, 330 mL, 350 mL, or 500 mL.

[0067] Lacquer finish Subsequently, the beverage can body may optionally be subjected to a lacquering step of block 206. The lacquering step can apply a coating to the beverage can body at a temperature of 150°C to 400°C for 1 second to 10 minutes. For example, the beverage can body may be lacquered at temperatures of 150°C to 400°C, 200°C to 400°C, 250°C to 350°C, 200°C to 300°C, or 300°C to 400°C. The peak metal temperature of the beverage can body during lacquering is 100°C to 300°C (e.g., 125°C to 275°C, 150°C to 250°C, or 200°C to 300°C).

[0068] Examples Example 1: The aluminum alloy contains up to 0.70 wt% Si, up to 0.80 wt% Fe, up to 0.60 wt% Cu, 0.80 to 2.00 wt% Mn, 1.30 to 1.50 wt% Mg, up to 0.60 wt% Zn, up to 0.30 wt% Cr, up to 0.10 wt% Ti, up to 0.15 wt% impurities, and Al, and the aluminum alloy contains more than 60 wt% recycled aluminum scrap.

[0069] Example 2: An aluminum alloy as described in Example 1, comprising 0.20-0.40 wt% Si, 0.40-0.60 wt% Fe, 0.10-0.30 wt% Cu, 0.80-1.0 wt% Mn, 1.35-1.50 wt% Mg, up to 0.25 wt% Zn, up to 0.05 wt% Cr, up to 0.05 wt% Ti, up to 0.15 wt% impurities, and Al.

[0070] Example 3: The aluminum alloy described in Example 1, containing more than 75% by weight of recycled aluminum scrap.

[0071] Example 4: The aluminum alloy described in Example 1, containing less than 15% by weight of primary aluminum.

[0072] Example 5: The aluminum alloy described in Example 4, containing less than 5% by weight of primary aluminum.

[0073] Example 6: An aluminum alloy according to any of Examples 1 to 5, exhibiting a yield strength of at least 200 MPa, preferably 200 to 350 MPa.

[0074] Example 7: An aluminum alloy according to any of Examples 1 to 6, exhibiting an ultimate tensile strength of at least 250 MPa, preferably 250 to 450 MPa.

[0075] Example 8: An aluminum alloy as described in any of Examples 1-7, containing up to 100% by weight of recycled aluminum scrap.

[0076] Example 9: An aluminum alloy as described in any of Examples 1-8, in which recycled aluminum scrap includes used beverage can scrap.

[0077] Example 10: The aluminum alloy described in Example 9, wherein the used beverage can scrap contains a mixture of recycled metals from the can ends and can bodies.

[0078] Example 11: A can body component containing an aluminum alloy as described in any of Examples 1 to 10.

[0079] Example 12: A method for manufacturing an aluminum alloy product, comprising: casting an aluminum alloy, including the aluminum alloy of Example 1, to form a cast product; homogenizing the cast product; hot rolling the cast product to produce a hot-rolled product; cold rolling the hot-rolled product to produce an aluminum alloy product; and optionally annealing the aluminum alloy product.

[0080] Example 13: The method according to Example 12, wherein the casting step includes continuously casting an aluminum alloy to form a cast product.

[0081] Example 14: The method according to Example 12, wherein the casting step includes directly chill casting an aluminum alloy to form a cast product.

[0082] Example 15: The method of Example 12, further comprising lacquering and curing an aluminum alloy product.

[0083] Example 16: The method according to Example 12, wherein the aluminum alloy contains more than 75% by weight of recycled aluminum scrap.

[0084] Example 17: The method according to Example 12, wherein the aluminum alloy contains less than 15% by weight of primary aluminum.

[0085] Example 18: The method according to Example 17, wherein the aluminum alloy contains less than 5% by weight of primary aluminum.

[0086] Example 19: A metal product prepared by a method including any of Examples 12-18.

[0087] Example 20: A metal product described in Example 19, which is a can body component.

[0088] Example 21: The metal product according to Example 19, which is a beverage can comprising a can body member prepared using the aluminum alloy described in Example 1 and a can end member prepared using a 5xxx series aluminum alloy.

[0089] Example 22: The metal product described in Example 21, wherein the can end member is prepared using AA5182.

[0090] Example 23: The metal product according to Example 19, which is a beverage can comprising a can end member prepared using the aluminum alloy described in Example 1 and a can body member and / or can end member prepared using a 5xxx series aluminum alloy.

[0091] The following examples serve to further illustrate the present invention, but do not constitute any limitation thereof. On the contrary, it should be clearly understood that various embodiments, modifications, and equivalents can be relied upon, which may be suggested to those skilled in the art without departing from the spirit of the invention after reading the description herein.

[0092] During the tests described in the following examples, conventional procedures were followed unless otherwise specified. Some of these procedures are described below for illustrative purposes. [Examples]

[0093] Example 1 Aluminum alloy samples were tested to determine the properties of the aluminum alloys described herein. Comparative Examples 1-3 and Example 1 were prepared according to the methods described herein. Comparative Examples 1-3 were prepared from conventional 3xxx series aluminum alloys used as can body components. Specifically, Comparative Example 1 was prepared from AA3004 aluminum alloy, Comparative Example 2 was prepared from AA3104 aluminum alloy, and Comparative Example 3 was prepared from AA3104 aluminum alloy. Example 1 was prepared from the aluminum alloy described herein. Table 3 provides the aluminum alloy compositions of Comparative Examples 1-3 and Example 1. [Table 3]

[0094] As shown in Table 3, Comparative Examples 1-3 contain less Mg compared to Example 1. Since Example 1 has a similar composition to Comparative Example 3 (i.e., AA3104 aluminum alloy), these aluminum alloys can be produced from a large amount of recycled UBC scrap containing similar amounts of Fe, Si, Cu, and Mn. This eliminates the need to dilute the aluminum alloy of Example 1 with primary aluminum or add additional hardening elements, resulting in savings in manufacturing and environmental costs. Furthermore, maintaining an aluminum alloy composition that may be similar to AA3104 aluminum alloy simplifies the remelting process and reduces process changes during manufacturing. The aluminum alloy composition of Example 1 is similar to conventional AA3104 aluminum alloy for can body components, except for its higher Mg content, enabling a simpler remelting process that can form a complete loop while minimizing changes in alloy composition. [Table 4]

[0095] Furthermore, the recycled content is significantly higher because the need for primary aluminum or hardening elements is much less. In contrast, conventional 3xxx series aluminum alloys for can body component applications require dilution of the Mg content when cast from UBC. As shown in Table 4, Comparative Example 3 contains 6.90 wt% primary aluminum, while Example 1 contains 4.30 wt% primary aluminum. The aluminum alloys described herein have at least 2.70 wt% less primary aluminum content than AA3104 aluminum alloys, which can save substantial costs and improve sustainability through reduced use of primary aluminum. In addition, Example 1 can incorporate more UBC scrap instead of primary aluminum because the aluminum alloy can tolerate more Mg. For example, Comparative Example 3 contains 75.00 wt% UBC scrap, while Example 1 contains 77.90 wt% UBC scrap.

[0096] Furthermore, combining an increase in Mg content with a decrease in Cu and Mn levels increases the recycled content of the aluminum alloy while still providing properties comparable to current 3xxx series aluminum alloys for can shell component applications. The alloy composition can maintain equivalent physical properties to current 3xxx series aluminum alloys (e.g., AA3104) for can shell component applications while compensating for the large Mg content by slightly reducing Mn and Cu to increase the recycled content.

[0097] All patents, publications, and abstracts cited above are incorporated herein by reference in their entirety. Various embodiments of the present invention are described in relation to the achievement of various objectives of the present invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous changes and modifications thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

1. An aluminum alloy containing up to 0.70 wt% Si, up to 0.80 wt% Fe, up to 0.60 wt% Cu, 0.80 to 1.50 wt% Mn, 1.30 to 2.00 wt% Mg, up to 0.60 wt% Zn, up to 0.30 wt% Cr, up to 0.10 wt% Ti, up to 0.15 wt% impurities, and Al, Contains at least up to 60% by weight of recycled aluminum scrap, The aforementioned aluminum alloy.

2. The aluminum alloy according to claim 1, comprising 0.20 to 0.40 wt% Si, 0.40 to 0.60 wt% Fe, 0.10 to 0.30 wt% Cu, 0.80 to 1.0 wt% Mn, 1.35 to 1.50 wt% Mg, up to 0.25 wt% Zn, up to 0.05 wt% Cr, up to 0.05 wt% Ti, up to 0.15 wt% impurities, and Al.

3. The aluminum alloy according to claim 1, comprising more than 75% by weight of recycled aluminum scrap.

4. The aluminum alloy according to claim 1, comprising less than 15% by weight of primary aluminum.

5. The aluminum alloy according to claim 4, comprising less than 5% by weight of primary aluminum.

6. The aluminum alloy according to any one of claims 1 to 5, exhibiting a yield strength of at least 200 MPa, preferably 200 to 350 MPa.

7. An aluminum alloy according to any one of claims 1 to 6, exhibiting an ultimate tensile strength of at least 250 MPa, preferably 250 to 450 MPa.

8. An aluminum alloy according to any one of claims 1 to 7, comprising up to 100% by weight of recycled aluminum scrap.

9. The aluminum alloy according to any one of claims 1 to 8, wherein the recycled aluminum scrap includes used beverage can scrap.

10. The aluminum alloy according to claim 9, wherein the used beverage can scrap contains a mixture of recycled metals from the can ends and can bodies.

11. Packaging for food or beverages comprising the aluminum alloy described in any one of claims 1 to 10.

12. A can body member comprising the aluminum alloy described in any one of claims 1 to 10.

13. A method for manufacturing aluminum alloy products, A cast product is formed by casting an aluminum alloy, including the aluminum alloy described in claim 1. Homogenizing the aforementioned cast product, The process involves hot-rolling the aforementioned cast product to produce a hot-rolled product, The process involves cold-rolling the aforementioned hot-rolled product to produce an aluminum alloy, Optionally, the aluminum alloy product is annealed, The aforementioned method.

14. The method according to claim 13, wherein the casting step comprises continuously casting the aluminum alloy to form the cast product.

15. The method according to claim 13, wherein the casting step comprises directly chill casting the aluminum alloy to form the cast product.

16. The method according to claim 123, further comprising lacquering and curing the aluminum alloy product.

17. The method according to claim 13, wherein the aluminum alloy contains more than 75% by weight of recycled aluminum scrap.

18. The method according to claim 13, wherein the aluminum alloy contains less than 15% by weight of primary aluminum.

19. The method according to claim 18, wherein the aluminum alloy contains less than 5% by weight of primary aluminum.

20. A metal product prepared by a method comprising any one of claims 13 to 19.

21. The metal product according to claim 20, wherein the metal product is packaging for food or beverages.

22. The metal product according to claim 20, wherein the metal product is a can body member.

23. The metal product according to claim 20, wherein the metal product is a beverage can comprising a can body member prepared using the aluminum alloy described in claim 1 and a can end member prepared using a 5xxx series aluminum alloy.

24. The metal product according to claim 23, wherein the can end member is prepared using AA5182.

25. The metal product according to claim 20, wherein the metal product is a beverage can comprising a can end member prepared using the aluminum alloy described in claim 1 and a can body member and / or can end member prepared using a 5xxx series aluminum alloy.

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