Aluminum alloys produced from recycled aluminum alloy scrap

Abstract

Provided herein are novel aluminum alloy products and methods for making these alloys. The aluminum alloys described herein are produced using high-content recycled scrap. The recycled scrap may include used beverage can scrap and mixed-alloy scrap (e.g., automotive scrap containing one or more of the 5xxx, 6xxx, and / or 7xxx series aluminum alloys). Surprisingly, aluminum alloy products produced from aluminum alloys containing high-content recycled scrap described herein exhibit mechanical properties comparable to those exhibited by high-performance aluminum alloy products, such as high tensile strength, good formability without cracks and / or fractures, and / or high elongation before fracture.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 010,182, filed April 15, 2020, which is incorporated by reference in its entirety.

[0002] Provided herein are novel aluminum alloys, products made from these novel alloys, and methods of making these alloys and products. The novel aluminum alloys and products are suitable for a variety of applications, including automotive and electronics applications. The aluminum alloys are produced from various sources of recycled aluminum alloy scrap and exhibit high strength and formability. [Background technology]

[0003] There has long been interest in using recycled aluminum alloy scrap in the production of aluminum alloys. The incorporation of recycled scrap leads to a reduction in the costs and time associated with the production of primary aluminum, and the desirability of recycling. However, recycled scrap may contain high levels of certain unwanted elements, making it unsuitable for use in the preparation of high performance aluminum alloys. Strict restrictions on the composition and processing of many high performance aluminum alloy products greatly limit the amount and type of recycled aluminum alloy scrap that can be used. For example, recycled scrap may contain certain elements in amounts that affect the mechanical properties of the aluminum alloy, such as formability and strength. For these reasons, it is not practical to use large amounts of recycled scrap to produce certain aluminum alloys, especially for automotive parts that require tightly controlled aluminum alloy compositions.

[0004] Additionally, there are trade-offs based on the type of recycled aluminum alloy scrap used to produce the aluminum alloy. Traditionally, recycled scrap from metal casting facilities (e.g., internal scrap or wraparound scrap) or metal processing facilities (e.g., separated automobile scrap) may account for the majority of the recycled scrap content. For example, recycled scrap from metal casting facilities or metal processing facilities may account for up to 95% of the recycled scrap content. Recycled scrap (e.g., separated automobile scrap) recovered from metal casting facilities or metal processing facilities is a high-performance aluminum alloy with consistent composition and mechanical properties. Due to its consistency and properties, recycled scrap from these scrap sources is more expensive than other types of scrap (e.g., post-consumer scrap and mixed alloy scrap). For most aluminum alloys suitable for recycling, the majority of recycled scrap comes from metal casting facilities or metal processing facilities because post-consumer scrap may contain large amounts of impurities.

[0005] The use of recycled scrap from metal processing facilities is also limited because recycled scrap is typically provided as mixed aluminum alloy scrap (e.g., a mixture of different aluminum alloys). In particular, recycled scrap from metal processing facilities is used to produce aluminum alloys only if the various alloy systems (such as 5xxx, 6xxx, or 7xxx series aluminum alloys) of the recycled scrap are properly separated. For example, recycled scrap from metal processing facilities may contain a mixture of 5xxx series aluminum alloys, 6xxx series aluminum alloys, and 7xxx series aluminum alloys, which need to be separated before the production of new aluminum alloys. Mixed alloys are considered to be of little value in producing new aluminum alloys without effectively separating the mixed alloys. Thus, mixed aluminum alloy scrap is rarely used as recycled scrap to produce aluminum alloys.

[0006] Aluminum alloys produced using recycled aluminum alloy scrap, especially those that must have material properties within certain specification limits, are expensive in terms of time, space, and energy or require the use of large amounts of new material (e.g., primary aluminum) or high purity aluminum scrap (e.g., scrap separated from metal casting or metal processing facilities). Summary of the Invention

[0007] The embodiments of the invention encompassed are defined by the claims, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter of the invention should be understood by reference to the entire specification, any or all drawings, and appropriate portions of each claim.

[0008] Provided herein are novel aluminum alloys and aluminum alloy products, and methods of making these aluminum alloys and products. In some embodiments, the aluminum alloy includes 0.50-3.00 wt.% Mg, 0.10-3.50 wt.% Si, 0.01-0.60 wt.% Fe, up to 1.20 wt.% Cu, 0.10-0.90 wt.% Mn, up to 0.20 wt.% Cr, up to 0.20 wt.% Ti, up to 0.10 wt.% V, up to 1.00 wt.% Zn, up to 0.15 wt.% impurities, and Al. In some embodiments, the aluminum alloy includes 1.00 wt%-2.50 wt% Mg, 0.20 wt%-3.00 wt% Si, 0.15 wt%-0.50 wt% Fe, 0.001 wt%-0.90 wt% Cu, 0.20 wt%-0.80 wt% Mn, up to 0.15 wt% Cr, up to 0.10 wt% Ti, up to 0.08 wt% V, 0.001 wt%-0.50 wt% Zn, up to 0.15 wt% impurities, and Al. In some embodiments, the aluminum alloy includes 1.40 wt%-2.40 wt% Mg, 0.30 wt%-2.50 wt% Si, 0.20 wt%-0.40 wt% Fe, 0.05 wt%-0.75 wt% Cu, 0.40 wt%-0.70 wt% Mn, max 0.10 wt% Cr, max 0.05 wt% Ti, max 0.05 wt% V, 0.005 wt%-0.40 wt% Zn, max 0.15 wt% impurities, and Al. In some embodiments, the aluminum alloy comprises 1.00 wt%-3.00 wt% Mg, 0.10 wt%-0.90 wt% Si, 0.01 wt%-0.60 wt% Fe, up to 0.50 wt% Cu, 0.10 wt%-0.90 wt% Mn, up to 0.20 wt% Cr, up to 0.20 wt% Ti, up to 0.10 wt% V, up to 1.00 wt% Zn, up to 0.15 wt% impurities, and Al; where the aluminum alloy comprises up to 100% recycled scrap, and where the recycled scrap comprises at least 25% used beverage can scrap, based on the total weight of the recycled scrap.In some embodiments, the aluminum alloy includes 1.25% to 2.50% by weight Mg, 0.20% to 0.80% by weight Si, 0.15% to 0.50% by weight Fe, 0.01% to 0.30% by weight Cu, 0.20% to 0.80% by weight Mn, up to 0.15% by weight Cr, up to 0.10% by weight Ti, up to 0.05% by weight V, up to 0.50% by weight Zn, up to 0.15% by weight impurities, and Al. In some embodiments, the aluminum alloy comprises 1.60 wt%-2.40 wt% Mg, 0.30 wt%-0.60 wt% Si, 0.20 wt%-0.40 wt% Fe, 0.05 wt%-0.20 wt% Cu, 0.40 wt%-0.70 wt% Mn, up to 0.10 wt% Cr, up to 0.05 wt% Ti, up to 0.03 wt% V, up to 0.20 wt% Zn, up to 0.15 wt% impurities, and Al. In some embodiments, the ratio of Si:Mg by weight is 0.05:1 to 0.60:1. In some embodiments, the aluminum alloy has an excess Si content of -1.70 to 0.10. In some embodiments, the aluminum alloy comprises a Cu content of less than 0.20 wt%, a Si:Mg ratio of 0.20:1 to 0.45:1, and an excess Si content of -1.30 to 0. In some embodiments, the recycled scrap comprises at least 50% post-consumer beverage can scrap based on the total weight of the recycled scrap. In some embodiments, the recycled scrap comprises at least 25% mixed alloy scrap. In some embodiments, the mixed alloy scrap comprises one or more of 5xxx series aluminum alloys, 6xxx series aluminum alloys, and 7xxx series aluminum alloys. In some embodiments, the mixed alloy scrap comprises a ratio of 5xxx series aluminum alloys to 6xxx series aluminum alloys of 1:3 to 3:1. In some embodiments, the mixed alloy scrap comprises at least 18.75 wt. of 5xxx series aluminum alloys based on the total weight of the recycled scrap. In some embodiments, the mixed alloy scrap comprises at least 18.75 wt. % of 6xxx series aluminum alloys based on the total weight of the recycled scrap.In some embodiments, the aluminum alloy has a yield strength (Rp0.2) of 160 MPa to 250 MPa for the T4 temper when paint baked at a temperature of about 185° C. for about 20 minutes and tested according to ISO 6892-1 (2016) after a 2% prestrain. In some embodiments, the aluminum alloy has an elongation at break of at least 15%. In some embodiments, the aluminum alloy has an ar(10) value of at least 0.40 in all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction). In some embodiments, the aluminum alloy has a β bend angle of 40° to 100° for bendability testing according to specification VDA 238-100. In some embodiments, the aluminum alloy excludes primary aluminum alloys. The clad aluminum alloy product of any one of claims 12-14, wherein the clad aluminum alloy product is a sheet, a plate, an electronic device housing, an automotive structural part, an aerospace structural part, an aerospace non-structural part, a marine structural part, or a marine non-structural part. In some embodiments, the aluminum alloy is produced from a process including homogenizing, hot rolling, cold rolling, solution treating, pre-aging, and artificial aging. In some embodiments, the aluminum alloy is cold coiled after hot rolling. In some embodiments, the aluminum alloy comprises at least 75% recycled scrap. In some embodiments, the aluminum alloy comprises recycled scrap from one or more post-consumer aluminum products, mixed automotive scrap, UBC scrap, twitch, and heat exchanger scrap. In some embodiments, the recycled scrap comprises end-of-life aluminum articles, and the end-of-life aluminum articles are obtained from aluminum-intensive vehicles. In some embodiments, the recycled scrap comprises 100% of scrap derived from end-of-life aluminum products. In some embodiments, the recycled scrap comprises heat exchanger scrap, the heat exchanger scrap comprises braze alloy scrap, In some embodiments, the recycled scrap comprises mixed automotive scrap, the mixed automotive scrap comprises recycled scrap from wrought and cast alloys.In some embodiments, the aluminum alloy comprises up to 25% primary aluminum alloy.

[0009] Other objects and advantages will become apparent from the following detailed description of non-limiting examples. [Brief description of the drawings]

[0010] [Figure 1] 1 is a graph of solvus and solidus temperatures (° C.) of aluminum alloy samples described herein. [Diagram 2] 1 is a graph of solidus temperature (° C.) as a function of weight percent of recycled scrap in aluminum alloy samples described herein. [Figure 3A] 1 is a graph of the ultimate tensile strength (Rm) and yield strength (Rp0.2) (both measured in MPa) of aluminum samples after batch annealing (e.g., after batch annealing at 330° C. for 2 hours). [Figure 3B] 1 is a graph of the ultimate tensile strength (Rm) and yield strength (Rp0.2) (both measured in MPa) of aluminum samples after continuous annealing and solution heat treatment at 550° C. for 0 seconds. [Figure 3C] 1 is a graph of the ultimate tensile strength (Rm) and yield strength (Rp0.2) (both measured in MPa) of aluminum samples after continuous annealing and solution heat treatment at 550° C. for 60 seconds. [Figure 4A] 1 is a graph of total elongation (A80) and uniform elongation (Ag) (both measured in %) of aluminum samples after batch annealing (e.g., after batch annealing at 330° C. for 2 hours). [Figure 4B] 1 is a graph of the total elongation (A80) and uniform elongation (Ag) (both measured in %) of an aluminum sample after continuous annealing and solution heat treatment at 550° C. for 0 seconds. [Figure 4C] 1 is a graph of the total elongation (A80) and uniform elongation (Ag) (both measured in %) of an aluminum sample after continuous annealing and solution heat treatment at 550° C. for 60 seconds. [Figure 5A]1 is a graph showing r(8-12) and n(10-15) values ​​of aluminum alloy samples after batch annealing (eg, after batch annealing at 330° C. for 2 hours). [Figure 5B] 1 is a graph showing the r(8-12) value and the n(10-15) value of an aluminum alloy sample after continuous annealing at 550° C. for 0 seconds and solution heat treatment. [Figure 5C] 1 is a graph showing the r(8-12) and n(10-15) values ​​of aluminum alloy samples after continuous annealing at 550° C. for 60 seconds and solution treatment. [Figure 6A] 1 is a graph showing the β bend angle (measured in degrees (°)) according to specification VDA 238-100 for aluminum alloys after batch annealing (e.g., after batch annealing at 330° C. for 2 hours). [Figure 6B] 1 is a graph showing the β bend angle (measured in degrees (°)) according to specification VDA 238-100 for aluminum alloys after continuous annealing and solution heat treatment at 550° C. for 0 seconds. [Figure 6C] 1 is a graph showing the β bend angle (measured in degrees (°)) according to specification VDA 238-100 for aluminum alloys after continuous annealing and solution heat treatment at 550° C. for 60 seconds. [Figure 7A] 1 is a graph of yield strength (Rp0.2) of an aluminum alloy specimen in a T8x temper (y-axis) after batch annealing (e.g., after batch annealing at 330° C. for 2 hours) (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% pre-strain at a temperature of about 185° C.), and in a T4 temper (x-axis) (both measured in MPa). [Figure 7B] 1 is a graph of the yield strength (Rp0.2) of an aluminum alloy specimen in a T8x temper (y-axis) after continuous annealing and solution heat treatment at 550°C for 0 seconds (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% prestrain at a temperature of about 185°C), and in a T4 temper (x-axis) (both measured in MPa). [Figure 7C]1 is a graph of the yield strength (Rp0.2) of an aluminum alloy specimen in a T8x temper (y-axis) after continuous annealing and solution treatment at 550°C for 60 seconds (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% pre-strain at a temperature of about 185°C), and in a T4 temper (x-axis) (both measured in MPa). [Figure 8A] 1 is a graph showing the β bend angle according to specification VDA 238-100 (measured in degrees (°)) of an aluminum alloy sample in T8x temper after batch annealing (e.g., after batch annealing at 330° C. for 2 hours), and the yield strength (Rp0.2) (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% pre-strain at a temperature of about 185° C.). [Figure 8B] 1 is a graph showing the β bend angle according to specification VDA 238-100 (measured in degrees (°)) of an aluminum alloy sample in T8x temper after continuous annealing and solution heat treatment at 550° C. for 0 seconds, and yield strength (Rp0.2) (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% prestrain at a temperature of about 185° C.). [Figure 8C] 1 is a graph showing the β bend angle according to specification VDA 238-100 (measured in degrees (°)) of aluminum alloy samples in T8x temper after continuous annealing and solution heat treatment at 550° C. for 60 seconds, and yield strength (Rp0.2) (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% prestrain at a temperature of about 185° C.). [Figure 9A] 1 is a graph of uniform elongation (Ag) (measured in %) as a function of the wt % UBC used to produce aluminum alloy samples after batch annealing (e.g., after batch annealing at 330° C. for 2 hours). [Figure 9B] 1 is a graph of uniform elongation (Ag) (measured in %) as a function of weight % UBC used to produce aluminum alloy samples after continuous annealing at 550° C. for 0 seconds and solution heat treatment. [Figure 9C] 1 is a graph of uniform elongation (Ag) (measured in %) as a function of weight % UBC used to prepare aluminum alloy samples after continuous annealing at 550° C. for 60 seconds and solution heat treatment. [Figure 10A]1 is a graph showing r(8-12) values ​​as a function of the wt. % UBC used to produce aluminum alloy samples after batch annealing (e.g., after batch annealing at 330° C. for 2 hours). [Figure 10B] 1 is a graph showing r(8-12) values ​​as a function of wt. % UBC used to prepare aluminum alloy samples after continuous annealing at 550° C. for 0 seconds and solution heat treatment. [Figure 10C] 1 is a graph showing r(8-12) values ​​as a function of wt. % UBC used to prepare aluminum alloy samples after continuous annealing at 550° C. for 60 seconds and solution heat treatment. [Figure 11] 1 is a graph of uniform elongation (Ag) (measured in %) of aluminum alloy samples as a function of Si+Mn-(Fe / 2) content in the aluminum alloy composition. [Figure 12] 1 is a graph of yield strength (Rp0.2) of aluminum alloy specimens in the T8x temper (y-axis) as a function of Si+Mn-(Fe / 2) content in the aluminum alloy composition (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% pre-strain at a temperature of about 185° C.). [Figure 13] 1 is a graph of the yield strength (Rp0.2) of an aluminum alloy specimen in a T8x temper (y-axis) (e.g., Rp0.2 after heat treatment for about 20 minutes after 2% pre-strain at a temperature of about 185°C) and the yield strength (Rp0.2) of an aluminum specimen in a T4 temper (x-axis) after continuous annealing and solution heat treatment at 550°C for 60 seconds (both measured in MPa). [Figure 14] 1 is a graph of the total elongation (A80) and uniform elongation (Ag) (both measured in %) of an aluminum sample after continuous annealing and solution heat treatment at 550° C. for 60 seconds. [Figure 15] 1 is a graph showing the n(4-6) and n(10-20) values ​​of aluminum alloy samples after continuous annealing and solution heat treatment at 550° C. for 60 seconds. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Described herein are aluminum alloys prepared from recycled aluminum alloy scrap (also referred to herein as "recycled scrap"). The recycled scrap can be used to produce aluminum alloys with mechanical properties (such as strength and formability) suitable for use in a variety of applications, such as automotive applications (such as hood inners) and household products (such as cookware such as pots and pans). Aluminum alloys can be produced from recycled scrap collected from a variety of sources and maintain desirable properties, such as desirable mechanical properties. Surprisingly, aluminum alloy products produced from aluminum alloys with high content of recycled scrap described herein exhibit mechanical properties comparable to those exhibited by high performance aluminum alloy products, such as high tensile strength, good formability without cracks and / or fractures, and / or high elongation before fracture.

[0012] The aluminum alloys described herein are produced using high content recycled scrap. In some embodiments, the recycled scrap may include at least 25% used beverage can (UBC) scrap and / or mixed alloy scrap (e.g., automotive scrap including one or more of 5xxx, 6xxx, and / or 7xxx series aluminum alloys). Traditionally, existing aluminum alloys, especially for automotive applications, have only been produced using standard automotive scrap, wraparound scrap, primary aluminum, and additional alloying elements (e.g., Si, Cu, Mn, Mg, etc.). This is because using UBC scrap and mixed alloy scrap is difficult to remelt into standard aluminum alloys for automotive parts with controlled compositions that achieve specific mechanical properties. Using large amounts of UBC scrap in combination with mixed alloy scrap, as described herein, can achieve desirable mechanical properties (e.g., tensile strength, formability, elongation before break, etc.) while using very low-cost recycled scrap. Environmentally friendly process. The new aluminum alloys described herein are produced from very low-cost recycled scrap materials and achieve properties comparable to other aluminum alloys for automotive parts.

[0013] In some embodiments, the aluminum alloys described herein are produced from 100% recycled scrap. This means that the aluminum alloys do not contain primary aluminum, leading to significant cost savings and a much lower environmental impact due to the significant energy consumption involved in the production of primary aluminum. The aluminum alloys can be produced from a combination of UBC scrap and mixed alloy scrap. Surprisingly, the aluminum alloys produced from these recycled scrap materials exhibit both high strength and formability for use in automotive applications. The aluminum alloys described herein also exhibit good tensile properties, bendability, and deep drawability.

[0014] In some embodiments, the aluminum alloys described herein are produced from mixed alloy scrap, including one or more end-of-life (EOL) aluminum articles (e.g., aluminum-intensive vehicles), non-segregated automotive scrap (e.g., including one or more 5xxx, 6xxx, and / or 7xxx series aluminum alloys from forging and casting alloys), twitches, and recycled aluminum alloy parts (e.g., heat exchangers, brazing alloy scrap, etc.). Mixed alloy scrap is very low cost, and using mixed alloy scrap to produce aluminum alloys can provide significant cost savings and reduce overall carbon emissions. Using these recycled aluminum alloy materials, as described herein, can achieve desirable mechanical properties while using very low cost recycled scrap.

[0015] High formability can be measured, for example, by measuring elongation at break or uniform elongation. ISO / EN A80 is one suitable standard that can be used to test elongation at break (EN 10002 parts 1-5, (2001)). ISO / EN Ag is one suitable standard that can be used to test uniform elongation. For example, the described aluminum alloys can have an elongation at break (A80) of at least 15% (e.g., 15% to 30%). In some examples, the described aluminum alloys can have a uniform elongation (Ag) of at least 15% (e.g., 15% to 22%). The elongation at break and uniform elongation are considered as the mathematical average of the elongations in the longitudinal (L), diagonal (D), and transverse (T) directions.

[0016] Another means for measuring formability is the r-value (also known as the Lankford modulus), which is the plastic strain ratio during tensile testing. The r-value is a measure of the deep drawability of a sheet metal (i.e., the resistance of a material to thinning or thickening when subjected to tension or compression). The r-value may be measured, for example, according to ISO 10113 (2006) or according to ASTM E517 (2019). An r-value measured over a strain range of 10% to 15% is denoted as r(10-15). For example, the described aluminum alloys may have an r(8-12) value of at least 0.50 (e.g., from 0.50 to 0.80).

[0017] The n-value, or strain hardening exponent, gives an indication of how much a material hardens or becomes stronger when plastically deformed. The n-value may be measured, for example, using ISO 10275 (2007) or according to ASTM E646 (2016). An n-value measured over a strain range of 10% to 15% is designated as n(10-15). For example, the described aluminum alloys may have an n(10-15) value of at least about 0.18 (e.g., from about 0.18 to about 0.28).

[0018] In addition to these performance characteristics, the recycled scrap used to produce the aluminum alloys described herein surprisingly requires little or no primary aluminum material. For example, scrap from aluminum intensive vehicles ("AIV") and mixed alloy scrap resulting from shredded aluminum body structures are suitable for producing new aluminum alloys without significant dilution with primary 5xxx series aluminum alloys and / or primary 6xxx series aluminum alloys. Additionally, non-segregated automotive scrap (e.g., forged and cast alloys), heat exchanger scrap, and brazing alloy scrap can be utilized to produce the aluminum alloys described herein. In some embodiments, the EOL aluminum article can be recycled scrap material derived from AIV. Recycled scrap from EOL aluminum products can be used in combination with various scrap streams, such as twitch, mixed automotive scrap, brazing alloy scrap, UBC scrap, etc., to produce aluminum alloys with superior mechanical properties.

[0019] Surprisingly, the aluminum alloys described herein can be produced from low-cost recycled scrap and still exhibit high strength (e.g., after paint bake) and high formability.

[0020] Definitions and Explanations: As used herein, the terms "invention," "the invention," "this invention," and "the present invention" are intended to refer broadly to all of the subject matter of this patent application and the claims that follow. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the claims that follow.

[0021] References are made herein to alloys identified by AA numbers and other related designations, such as "series" or "5xxx." For an understanding of the numbering systems most commonly used to name and identify aluminum and its alloys, please refer to "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot" (both published by The Aluminum Association).

[0022] As used herein, plate typically has a thickness of greater than about 15 mm. For example, plate can refer to an aluminum product having a thickness of greater than 15 mm, greater than 20 mm, greater than 25 mm, greater than 30 mm, greater than 35 mm, greater than 40 mm, greater than 45 mm, greater than 50 mm, or greater than 100 mm.

[0023] As used herein, a shade (also referred to as a sheet plate) typically has a thickness of about 4 mm to about 15 mm. For example, the shade may have a thickness of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.

[0024] As used herein, sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the sheet may have a thickness of less than 4 mm, 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.

[0025] In this application, reference is made to alloy tempers or tempers. For an understanding of the descriptions of the most commonly used alloy tempers, please refer to "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems". The F temper or temper refers to the aluminum alloy as produced. The W temper or temper refers to the aluminum alloy that has been solution heat treated above the solvus temperature of the aluminum alloy and then quenched. The O temper or temper refers to the aluminum alloy after annealing. The Hxx temper or temper, also referred to herein as the H temper, refers to an aluminum alloy that is not heat treatable after cold rolling, with or without heat treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8, or HX9 tempers. The T1 temper or temper refers to an aluminum alloy that has been cooled from hot working and naturally aged (e.g., at room temperature). The T2 temper or temper refers to an aluminum alloy that has been cooled from hot working, cold worked, and naturally aged. The T3 temper or temper refers to an aluminum alloy that has been solution treated, cold worked, and naturally aged. The T4 temper or temper refers to an aluminum alloy that has been solution treated and naturally aged. The T5 temper or temper refers to an aluminum alloy that has been cooled from hot working, and artificially aged (at an elevated temperature). The T6 temper or temper refers to an aluminum alloy that has been solution treated and artificially aged. The T7 temper or temper refers to an aluminum alloy that has been solution treated and artificially overaged. The T8x temper or temper refers to an aluminum alloy that has been solution treated, cold worked, and artificially aged. The T9 temper or temper refers to an aluminum alloy that has been solution treated, artificially aged, and cold worked.

[0026] As used herein, the terms "cast metal product," "cast product," "cast aluminum alloy product," and the like are used interchangeably and refer to products produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, twin roll caster, block caster, or any other casting machine), electromagnetic casting, hot top casting, or any other casting process.

[0027] As used herein, the meaning of "room temperature" can include a temperature of about 15° C. to about 30° C., e.g., about 15° C., about 16° C., about 17° C., about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30° C. As used herein, the meaning of "ambient conditions" can include a temperature of about room temperature, a relative humidity of about 20% to about 100%, and an atmospheric pressure of about 975 millibars (mbar) to about 1050 mbar. For example, the relative humidity may be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, about 101%, about 102%, about 103%, about 104%, about 105%, about 106%, about 107%, about 108%, about 109%, about 110%, about 111%, about 112%, about 113%, about 114%, about 115%, about 116%, about It can be 1%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anything therebetween. For example, the air pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anything therebetween.

[0028] All ranges disclosed herein should be understood to encompass any and all subranges subsumed therein. For example, the stated range "1 to 10" should be considered to encompass any and all subranges between the minimum value of 1 and the maximum value of 10 (and inclusive), i.e., all subranges beginning with a minimum value of 1 or more (e.g., 1 to 6.1) and ending with a maximum value of 10 or less (e.g., 5.5 to 10). The term "about" is inclusive of the exact value.

[0029] As used herein, the meanings of "a," "an," and "the" include singular and plural references unless the context clearly dictates otherwise.

[0030] As used herein, the term recycled scrap can refer to a collection of recycled metals. Recycled scrap can include materials recycled from suitable post-consumer sources (such as local recycling facilities), such as metal manufacturing facilities (e.g., metal casting facilities), metal processing facilities (e.g., production facilities that use metal products to manufacture consumable products), and the like.

[0031] As used herein, used beverage cans (UBC) refers to any used beverage can scrap known in the art, such as those described in the Scrap Specifications Circular (2018) issued by Scrap Recycling Industries, Inc., including shredded aluminum UBC scrap, densified aluminum UBC scrap, baled aluminum UBC scrap, and / or briquette aluminum UBC scrap.

[0032] As used herein, "twitch" refers to fragmented aluminum scrap. Twitch may be produced by a float process in which the scrap is submerged in water. The aluminum scrap floats to the top and the heavier pieces of scrap metal sink. For example, some processes may include mixing sand into the water to change the density of the water in which the scrap is submerged.

[0033] As used herein, "aluminum intensive vehicle" (AIV) refers to a vehicle that contains a significant portion of aluminum alloy.

[0034] Throughout the application, aluminum alloys and aluminum alloy products and their components are described in terms of their elemental composition in weight percent (wt%). In some embodiments, the balance of the alloy is aluminum with a maximum wt% of all impurities total of 0.50% (e.g., maximum 0.45 wt%, maximum 0.40 wt%, maximum 0.35 wt%, maximum 0.30 wt%, maximum 0.25 wt%, maximum 0.20 wt%, maximum 0.15 wt%, and / or maximum 0.10 wt%).

[0035] Recycled alloys The aluminum alloys described herein can be produced entirely from recycled scrap (e.g., 100% recycled scrap). In some embodiments, the aluminum alloys described herein can be produced from a combination of different recycled scrap materials. Recycled aluminum alloy scrap (e.g., recycled scrap) can be obtained from a variety of sources at all stages of the aluminum life cycle. In some cases, recycled scrap can refer to a collection of recycled metals. Recycled scrap can include materials recycled from suitable sources, such as metal manufacturing facilities (e.g., metal casting facilities), metal processing facilities (e.g., production facilities that use metal products to manufacture consumables), or post-consumer sources (e.g., local recycling facilities). For example, internal scrap may be generated during the production of aluminum alloys at metal casting facilities (e.g., scrap from the production of aluminum ingots, billets, sheet, plate, etc.), customer scrap may be generated during stamping, milling, and other processes at metal fabrication facilities (e.g., scrap from the creation of can bodies, can ends, auto parts, etc.), and post-consumer scrap may be generated from aluminum products used by consumers and collected at local recycling facilities (e.g., used beverage cans, used auto parts, etc.). Each of these types of recycled scrap is a substitute for primary aluminum metal.

[0036] The aluminum alloys described herein can withstand larger amounts of post-consumer scrap and mixed alloy scrap and still exhibit desirable mechanical properties. The impact of impurities and / or alloying elements on the mechanical properties of the aluminum alloys is reduced by providing a specific mixture of recycled scrap to compensate for the impurities. This allows for the use of larger amounts of less expensive, more impure aluminum scrap (e.g., post-consumer scrap and mixed alloy scrap) to produce aluminum alloys that can still exhibit desirable properties. The aluminum alloy compositions described herein allow for the use of larger amounts of post-consumer scrap and mixed alloy scrap with little or no additional primary aluminum, and for the reduction of the amount of more expensive recycled scrap (e.g., segregated scrap from metal casting facilities).

[0037] The amount of recycled content is reduced and costs are higher because the addition of primary aluminum is more expensive to produce than recycled scrap. Therefore, a trade-off is often made between limiting the amount of recycled scrap and adding primary aluminum to achieve certain mechanical properties. Furthermore, producing primary aluminum alloys generates significant carbon emissions compared to producing new aluminum alloys from recycled scrap.

[0038] Additionally, trade-offs exist based on the type of recycled scrap used to produce the aluminum alloy. Traditionally, separated recycled scrap from metal casting facilities (e.g., internal scrap or wraparound scrap) or metal processing facilities (e.g., segregated automotive scrap) can comprise the majority of the recycled scrap content. However, mixed alloy scrap from metal processing facilities is only used to produce aluminum alloys if the various alloy systems (e.g., 5xxx or 6xxx series aluminum alloys) of the recycled scrap are properly separated. Mixed alloys are of little value in producing new aluminum alloys without effectively separating the mixed alloys. Thus, when recycled scrap is used to produce aluminum alloys, a maximum of 5% of the material is post-consumer scrap or mixed alloy scrap, and the remainder is other types of recycled aluminum alloy material (e.g., internal scrap, wraparound scrap, or segregated scrap). Post-consumer scrap and mixed alloys can contain impurities and certain alloying elements (e.g., high content of Cu, Fe, or Mn) that make it difficult to control the composition of the aluminum alloy.

[0039] Certain embodiments of the present disclosure may be well suited for producing aluminum alloys using a combination of post-consumer scrap (e.g., UBC scrap) and mixed alloy scrap. Post-consumer scrap includes recycled sheet aluminum products (e.g., aluminum pots and pans), recycled cast aluminum products (e.g., aluminum grills and wheel rims), used beverage can ("UBC") scrap, recycled aluminum such as aluminum wire, end-of-life aluminum alloy products (e.g., aluminum intensive vehicles, heat exchangers, etc.), and other aluminum materials.

[0040] The aluminum alloy compositions described herein can reduce the amount of higher volume post-consumer scrap and mixed alloy scrap with little or no additional primary aluminum, and more expensive recycled scrap (e.g., separated scrap from metal casting or metal processing facilities). For example, the aluminum alloys can be produced from recycled scrap that contains at least 25% post-consumer scrap (e.g., 25%-100%, 30%-100%, 40%-100%, 50%-100%, 60%-100%, or 75%-100% post-consumer scrap). For example, the aluminum alloys can contain more than 25% post-consumer scrap, e.g., more than 30%, more than 35%, more than 40%, more than 45%, more than 50%, more than 55%, more than 60%, more than 65%, more than 70%, or more than 75% post-consumer scrap. All expressed in weight percent. The high post-consumer scrap content leads to significant cost savings and allows the production of aluminium alloys on a 100% recycled basis.

[0041] In some embodiments, the aluminum alloys described herein include a large amount of UBC scrap with 25% or more UBC, e.g., 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, or 75% or more. In terms of ranges, the aluminum alloys described herein can include 25%-100% UBC scrap (e.g., 25%-100%, 30%-100%, 40%-100%, 50%-100%, 60%-100%, or 75%-100%).

[0042] Aluminum UBC scrap is often a mixture of various aluminum alloys (e.g., from different alloys used for can bodies and can ends), which often may include extraneous materials such as rainwater, beverage residues, organic materials (e.g., paints and laminate films), and other materials. UBC scrap typically contains a mixture of metals from various alloys, such as metals from can bodies (e.g., 3104, 3004, or other 3xxx aluminum alloys) and can ends (e.g., 5182 or other 5xxx aluminum alloys). UBC scrap may be shredded, decoated, or depainted before being melted for use as liquid metal stock in the casting of new metal products.

[0043] In some embodiments, the aluminum alloys described herein can include mixed alloy scrap. In some embodiments, the mixed alloy scrap includes mixed automotive scrap. In some embodiments, the mixed alloy scrap includes recycled scrap from end-of-life aluminum alloy products (e.g., aluminum intensive vehicles, heat exchangers, etc.). The mixed alloy scrap can be derived from wrought alloys, cast alloys, and extrusion alloys. For example, the aluminum alloy can include recycled 5xxx series aluminum alloy scrap. As another example, the aluminum alloy can be produced from mixed alloy scrap including 6xxx series aluminum alloys. As yet another example, the aluminum alloy can be produced from mixed alloy scrap including 7xxx series aluminum alloys. As another example, the aluminum alloy can include recycled 6xxx series aluminum alloy scrap or both 5xxx series aluminum alloy scrap and 6xxx series aluminum alloy scrap. In some cases, the 5xxx series aluminum alloy is the primary alloy in the mixed alloy scrap. In other cases, the 6xxx series aluminum alloy is the dominant alloy in the mixed alloy scrap. In other cases, the 7xxx series aluminum alloy is the dominant alloy in the mixed alloy scrap. In some cases, 5xxx, 6xxx, and 7xxx series aluminum alloys are present in equal amounts in the mixed alloy scrap. In some embodiments, aluminum alloys can be produced from recycled scrap containing 0%-75% mixed alloy scrap (e.g., 5%-70%, 10%-65%, 15%-60%, 20%-50%, or 25%-40% mixed alloy scrap) based on the total weight of the recycled scrap. For example, aluminum alloys can be produced from recycled scrap containing more than 0% mixed alloy scrap (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0044] As noted above, in some embodiments, the recycled scrap includes mixed alloy scrap including two or more of 5xxx series aluminum alloy scrap, 6xxx series aluminum alloy scrap, and 7xxx series aluminum alloy scrap. In some embodiments, the recycled scrap can include 5xxx series aluminum alloy scrap (from mixed alloy scrap) in an amount of 0%-75% (e.g., 5%-70%, 10%-65%, 15%-60%, 20%-50%, or 25%-40%) based on the total weight of the recycled scrap. For example, the recycled scrap can include more than 0% 5xxx series aluminum alloy scrap (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0045] In some embodiments, the recycled scrap may contain 6xxx series aluminum alloy scrap (from mixed alloy scrap) in an amount between 0% and 75% (e.g., between 5% and 70%, between 10% and 65%, between 15% and 60%, between 20% and 50%, or between 25% and 40%) based on the total weight of the recycled scrap. For example, the recycled scrap may contain greater than 0% 6xxx series aluminum alloy scrap (e.g., greater than 1%, greater than 5%, greater than 10%, greater than 15%, greater than 20%, or greater than 25%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0046] In some embodiments, the recycled scrap may contain 7xxx series aluminum alloy scrap (from mixed alloy scrap) in an amount between 0% and 75% (e.g., between 5% and 70%, between 10% and 65%, between 15% and 60%, between 20% and 50%, or between 25% and 40%) based on the total weight of the recycled scrap. For example, the recycled scrap may contain greater than 0% 7xxx series aluminum alloy scrap (e.g., greater than 1%, greater than 5%, greater than 10%, greater than 15%, greater than 20%, or greater than 25%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0047] Non-limiting exemplary 5xxx series aluminum alloys for use as aluminum alloy products include AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA511 9A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA51 49, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A , AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5 654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA555 AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0048] Examples of suitable 6xxx series aluminum alloy compositions for use in the aluminum alloy products described herein include, for example, AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA 6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027 , AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA605 3, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6 AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, and AA6092 compositions.

[0049] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein include AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA A7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, A A7049A, AA7149, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155 , AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0050] In some embodiments, the mixed alloy scrap may include recycled scrap from EOL aluminum alloy articles. In some embodiments, the recycled scrap from EOL aluminum alloy products may include multiple series of aluminum alloys. For example, recycled scrap from EOL aluminum alloy products may include 5xxx series aluminum alloy scrap, 6xxx series aluminum alloy scrap, and / or 7xxx series aluminum alloy scrap from wrought or cast aluminum alloys. In some embodiments, the mixed alloy scrap may include EOL aluminum alloy articles, unsegregated automotive scrap, twitch, braze alloy scrap, and / or UBC.

[0051] In some embodiments, the recycled scrap may include scrap from EOL aluminum alloy articles, mixed automobile scrap, twitch, heat exchanger scrap, brazing alloy scrap, UBC scrap, or combinations thereof. In some embodiments, the EOL aluminum article may include aluminum-intensive vehicles. The recycled scrap from aluminum-intensive vehicles may include one or more of 5xxx series aluminum alloys, 6xxx series aluminum alloys, and 7xxx series aluminum alloys from cast and extruded alloys. The recycled scrap from twitch may include one or more of cast aluminum alloys and wrought aluminum alloys. The recycled scrap from heat exchangers may include 3xxx series aluminum alloys and 4xxx series aluminum alloys.

[0052] In some embodiments, the recycled scrap may include up to 100% EOL aluminum articles (e.g., 50%-100%, 55%-100%, 60%-100%, 70%-100%, 75%-100%, 80%-100%, or 90%-100%) based on the total weight of the recycled scrap. In some embodiments, the recycled scrap from EOL aluminum articles is derived from AIV.

[0053] In some embodiments, the recycled scrap may include mixed automobile scrap. The mixed automobile scrap may include the same materials as the mixed alloy scrap (e.g., one or more of the 5xxx, 6xxx, and / or 7xxx series aluminum alloys). In some embodiments, the recycled scrap may include mixed automobile scrap in an amount between 25% and 100% (e.g., between 30% and 95%, between 35% and 90%, between 40% and 85%, between 45% and 80%, between 50% and 75%, or between 55% and 80%) based on the total weight of the recycled scrap. For example, the recycled scrap may include more than 25% mixed automobile scrap (e.g., greater than 30%, greater than 35%, greater than 40%, greater than 45%, greater than 55%, or greater than 60%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0054] In some embodiments, the mixed auto scrap can be used in combination with one or more EOL aluminum articles, twitch, brazing alloy scrap (e.g., from heat exchangers), and UBC. In some embodiments, the recycled scrap can include twitch (in combination with the mixed auto scrap) in an amount between 0% and 60% (e.g., between 1% and 55%, between 5% and 50%, between 10% and 45%, between 15% and 40%, between 20% and 40%, or between 25% and 35%) based on the total weight of the recycled scrap. For example, the recycled scrap can include more than 0% twitch (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0055] In some embodiments, the recycled scrap may include UBC scrap (in combination with mixed auto scrap, twitch, and / or braze alloy scrap) in an amount between 0% and 50% (e.g., between 1% and 45%, between 5% and 40%, between 10% and 35%, between 15% and 40%, between 20% and 40%, or between 25% and 35%) based on the total weight of the recycled scrap. For example, the recycled scrap may include greater than 0% UBC scrap (e.g., greater than 1%, greater than 5%, greater than 10%, greater than 15%, greater than 20%, or greater than 25%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0056] In some embodiments, the recycled scrap may include brazing alloy scrap (in combination with mixed auto scrap, twitch, and / or UBC scrap) in an amount between 0% and 40% (e.g., between 1% and 35%, between 5% and 30%, between 10% and 40%, between 10% and 30%, between 15% and 40%, or between 20% and 35%) based on the total weight of the recycled scrap. For example, the recycled scrap may include greater than 0% brazing alloy scrap (e.g., greater than 1%, greater than 2%, greater than 5%, greater than 10%, greater than 15%, or greater than 20%) based on the total weight of the recycled scrap. All expressed in weight percent.

[0057] In some embodiments, primary aluminum alloys can be used in combination with recycled scrap to produce the aluminum alloys described herein. For example, up to 25% (e.g., up to 20%, up to 15%, up to 12%, up to 10%, up to 8%, up to 6%, up to 4%, up to 2%, or up to 1%) of primary aluminum alloys can be used to produce the aluminum alloys described herein. In some embodiments, primary aluminum alloys are not used in combination with recycled scrap.

[0058] Aluminum alloy composition (wt%) In some cases, the aluminum alloys described herein may have the following elemental compositions as shown in Table 1. [Table 1]

[0059] In some examples, the alloy may have the following elemental composition provided in Table 2. [Table 2]

[0060] In some examples, the alloy may have the following elemental composition as provided in Table 3. [Table 3]

[0061] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 4: [Table 4]

[0062] In some examples, the alloy may have the following elemental composition as provided in Table 5. [Table 5]

[0063] In some examples, the alloy may have the following elemental composition as provided in Table 6. [Table 6]

[0064] In some examples, the alloy may have the following elemental composition as provided in Table 7. [Table 7]

[0065] In some examples, the alloy may have the following elemental composition as provided in Table 8. [Table 8]

[0066] In some examples, the aluminum alloys described herein may include copper (Cu) in an amount of 0% to about 1.20% (e.g., about 0.001% to about 0.90%, about 0.05% to about 1.00%, about 0.05% to about 0.75%, about 0.10% to about 0.90%, about 0.20% to about 0.75%, about 0.01% to about 0.50%, about 0.01% to about 0.40%, about 0.05% to about 0.30%, or about 0.05% to about 0.20%) based on the total weight of the alloy. For example, alloys may be: 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%, 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%, 0.41%, 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 2%, 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%, 0.41%, 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%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0. It may contain 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%, 1.16%, 1.17%, 1.18%, 1.19%, or 1.20% Cu.All are expressed as weight percent.

[0067] In some examples, the aluminum alloys described herein include iron (Fe) in an amount between 0.01% and about 0.60% (e.g., between about 0.05% and about 0.55%, between about 0.10% and about 0.50%, between about 0.15% and about 0.45%, between about 0.20% and about 0.40%, between about 0.25% and about 0.40%, or between about 0.30% and about 0.40%) based on the total weight of the alloy. For example, alloys may be 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%, 0.41%, 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%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, The composition 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% Fe, all expressed as % by weight.

[0068] In some examples, the alloys described herein include magnesium (Mg) in an amount between about 0.50% and about 3.00% (e.g., between about 0.75% and about 2.75%, between about 1.00% and about 2.50%, between about 1.40% and about 2.40%, between about 1.20% and about 2.75%, between about 1.25% and about 2.50%, between about 1.50% and about 2.40%, or between about 1.60% and about 2.30%) based on the total weight of the alloy. For example, alloys may have the following properties: 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%, 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%, 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%, 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%, 1.66%, 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%, 2.00%, 2.01%, 2.02%, 2.03%, 2.04%, 2.05%, 2.06%, 2.07%, 2.08%, 2.09%, 2.10%, 2.11%, 2.12%, 2.13%, 2.14%, 2.15%, 2.16% ,2.17%,2.18%,2.19%,2.20%,2.21%,2.22%,2.23%,2.24%,2.25%,2.26%,2.27%,2.28%,2.29%,2.30%,2.31%,2.32%,2.33%,2.34%,2.35%,2.36%,2.37%,2.38%,2.39%,2.40%,2.41%,2.42%,2.43%,2.44%,2.45%,2.46%,2.47%,2.48%,2.49%,2.50%,2.51%,2.52%,2.53%,2.54%,2.55%,2.56%,2.57%,2.58%,2.59%,2.60%,2.61%,2.62%,2.63%,2.64%,2.65%,2.66%,2.67%,2.68%,2.69%,2.70%,2.71%,2.72%,2.73%,2.74%,2.75%,2.76%,2.77%,2.78%,2.79%,2.80%,2.81%,2.82%,2.83%,2.84%,2.85%,2.86%,2.87%,2.88%,2.89%,2.90%,2.91%,2.92%,2.93%,2.94%,2.95%,2.96%,2.97%,2.98%,2.99%,2. 5%, 2.46%, 2.47%, 2.48%, 2.49%, 2.50%, 2.51%, 2.52%, 2.53%, 2.54%, 2.55%, 2.56%, 2.57%, 2.58%, 2.59%, 2.60%, 2.61%, 2.62%, 2.63%, 2.64%, 2.65%, 2.66%, 2.67%, 2.68%, 2.69%, 2.70%, 2.71%, 2.72%, 2.73%, 2.74%, 2.75%, 2.76%, 2.77%, 2.78%, 2.79%, 2.80%, 2.81%, 2.82%, 2.83%, 2.84%, 2.85%, 2.86%, 2.87%, 2.88%, 2.89%, 2.90%, 2.91%, 2.92%, 2.93%, 2.94%, 2.95%, 2.96%, 2.97%, 2.98%, 2.99%, 3.00%, 3.01%, 3.02%, 3.03%, 3.04%, 3.05%, 3.06%, 3.07%, 3.08%, 3.09%, 3.10%, 3.11%, 3.12%, 3.13%, 3.14%, 3.15%, 3.16%, 3.17%, 3.18%, 3.19%, 3.20%, 3.21%, 3.22%, 3.23%, 3.24%, 3.25%, 3.26%, 3.27%, 3.28%, 3.29%, 3.3 The composition may contain 0.74%, 2.75%, 2.76%, 2.77%, 2.78%, 2.79%, 2.80%, 2.81%, 2.82%, 2.83%, 2.84%, 2.85%, 2.86%, 2.87%, 2.88%, 2.89%, 2.90%, 2.91%, 2.92%, 2.93%, 2.94%, 2.95%, 2.96%, 2.97%, 2.98%, 2.99%, or 3.00% Mg, all expressed as % by weight.

[0069] In some embodiments, the aluminum alloy can include manganese (Mn) in an amount of about 0.10% to about 0.90% (e.g., about 0.20% to about 0.80%, about 0.25% to about 0.75%, about 0.30% to about 0.70%, about 0.40% to about 0.70%, or about 0.50% to about 0.70%) based on the total weight of the alloy. For example, the alloy can include 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%, 0.32%, 0.36%, 0.38%, 0.39%, 0.40%, 0.42%, 0.46%, 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%, 0.80%, 0.81%, 0.82%, %,0.30%,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%,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%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, or 0.90% Mn, all expressed as weight percent.

[0070] In some examples, the aluminum alloys described herein may include silicon (Si) in an amount of about 0.10% to about 3.50% (e.g., about 0.15% to about 3.25%, about 0.20% to about 3.00%, about 0.30% to about 2.5%, about 0.20% to about 0.80%, about 0.25% to about 0.75%, about 0.30% to about 0.70%, about 0.30% to about 0.60%, about 0.40% to about 0.60%, or about 0.45% to about 0.55%) based on the total weight of the alloy. For example, alloys are: 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%, 0.41% ,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%, 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%, 2.10%, 2.11%, 2.12%, 2.13%, 2.14%, 2.15%, 2.16%, 2.17%, 2.18%, 2.19%, 2.20%, 2.21%, 2.22%, 2.23%, 2.24%, 2.25%, 2.26%, 2.27%, 2.28%, 2.29%, 2.30%, 2.31%, 2.32%, 2.33%, 2.34%, 2.35%, 2.36%, 2.37%, 2.38%, 2.39%, 2.40%, 2.41%, 2.42%, 2.43%, 2.44%, 2.45%, 2.46%, 2.47%, 2.48%, 2.49%, 2.50%, 2.51%, 2.52%, 2.53%, 2.54%, 2.55%, 2.56%, 2.57%, 2.58%, 2.59%, .08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 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%、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%、1.66%、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%、2.00%、2.01%、2.02%、2.03%、2.04%、2.05%、2.06%、2.07%、2.08%、2.09%、2.10%、2.11%、2.12%、2.13%、2.14%、2.15%、2.16%、2.17%、2.18%、2.19%、2.20%、2.21%、2.22%、2.23%、2.24%、2.25%、2.26%、2.27%、2.28%、2.29%、2.30%、2.31%、2.32%、2.33%、2.34%、2.35%、2.36%、2.37%、2.38%、2.39%、2.40%、2.41%、2.42%、2.43%、2.44%、2.45%、2.46%、2.47%、2.48%、2.49%、2.50%、2.51%、2.52%、2.53%、2.54%、2.55%、2.56%、2.57%、2.58%、2.59%、2.60%、2.61%、2.62%、2.63%、2.64%、2.65%、2.66%、2.67%、2.68%、2.69%、2.70%、2.71%、2.72%、2.73%、2.74%、2.75%、2.76%、2.77%、2.78%、2.79%、2.80%、2.81%、2.82%、2.83%、2.84%、2.85%、2.86%、2.87%、2.88%、2.89%、2.90%、2.91%、2.92%、2.93%、2.94%、2.95%、2.96%、2.97%、2.98%、2.99%、3.00%、3.01%、3.02%、3.03%、3.04%、3.05%、3.06%、3.07%, 3.08%, 3.09%, 3.10%, 3.11%, 3.12%, 3.13%, 3.14%, 3.15%, 3.16%, 3.17%, 3.18%, 3.19%, 3.20%, 3.21%, 3.22%, 3.23%, 3.24%, 3.25%, 3.26%, 3.27%, 3.28%, 3.29%, It may contain 3.30%, 3.31%, 3.32%, 3.33%, 3.34%, 3.35%, 3.36%, 3.37%, 3.38%, 3.39%, 3.40%, 3.41%, 3.42%, 3.43%, 3.44%, 3.45%, 3.46%, 3.47%, 3.48%, 3.49%, or 3.50% Si, all expressed as weight percent.

[0071] In some examples, the aluminum alloys described herein may include zinc (Zn) in an amount of 0% to about 1.00% (e.g., about 0.001% to about 1.00%, about 0.001% to about 0.50%, about 0.005% to about 0.40%, about 0.01% to about 0.50%, about 0.05% to about 0.40%, or about 0.10% to about 0.35%) based on the total weight of the alloy. For example, alloys may be 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%, 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%, 0.41%, 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. 7%, 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%, 0.41%, 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. The alloy may contain 74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 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%, or 1.00% Zn. In some cases, Zn is absent (i.e., 0%) in the alloy. All percentages are expressed by weight.

[0072] In some examples, the aluminum alloys described herein may include between 0% and about 0.20% (e.g., between about 0.001% and about 0.15%, between about 0.005% and about 0.10%, between about 0.008% and about 0.08%, or between about 0.01% and about 0.05%) titanium (Ti) based on the total weight of the alloy. For example, the 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 is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0073] In some examples, the aluminum alloys described herein may include 0% to about 0.20% (e.g., 0% to about 0.10%, about 0.001% to about 0.10%, about 0.05% to about 0.08%, or about 0.01% to about 0.05%) chromium (Cr) based on the total weight of the alloy. For example, the 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% Cr. In some cases, Cr is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0074] In some examples, the aluminum alloys described herein may include vanadium (V) in an amount between 0% and about 0.10% (e.g., between 0% and about 0.08%, between 0% and about 0.05%, between about 0.001% and about 0.06%, between about 0.005% and about 0.05%, or between about 0.008% and about 0.02%) based on the total weight of the alloy. For example, the alloy may include 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%, or 0.10% V, all expressed in weight percent.

[0075] In some examples, the aluminum alloys described herein may include zirconium (Zr) in an amount between 0% and about 0.05% (e.g., between 0.0001% and about 0.02%, between about 0.002% and about 0.015%, between about 0.0003% and about 0.01%, or between about 0.0004% and about 0.001%) based on the total weight of the alloy. For example, the alloy may contain 0.0001%, 0.0002%, 0.0003%, 0.0004%, 0.0005%, 0.0006%, 0.0007%, 0.0008%, 0.0009%, 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%, or 0.05% Zr. In some cases, Zr is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0076] Optionally, the aluminum alloys described herein may further include other minor elements, sometimes referred to as impurities, in amounts of about 0.05% by weight or less, about 0.04% by weight or less, about 0.03% by weight or less, about 0.02% by weight or less, or about 0.01% by weight or less. These impurities may include, but are not limited to, Ni, Sc, Hf, Sn, Ga, Bi, Na, Pb, or combinations thereof. Thus, Ni, Sc, Hf, Zr, Sn, Ga, Bi, Na, or Pb may each be present in the alloy in an amount of about 0.05% by weight or less, about 0.04% by weight or less, about 0.03% by weight or less, about 0.02% by weight or less, or about 0.01% by weight or less. The sum of all impurities does not exceed about 0.50% by weight (e.g., not exceeding about 0.40%, about 0.30%, about 0.25%, about 0.20%, about 0.15%, or about 0.10% by weight), all expressed as weight percent. In some embodiments, the remaining percentage of the alloy is aluminum.

[0077] Thus, in some embodiments, the aluminum alloy can include 0.10 wt%-0.90 wt% Si and 1 wt%-3 wt% Mg. In some embodiments, the ratio of Si weight percent to Mg weight percent in the aluminum alloy (e.g., Si:Mg) can be 0.05:1-0.60:1 (e.g., 0.10:1-0.55:1, 0.15:1-0.50:1, 0.20:1-0.45:1, 0.20:1-0.40:1, 0.24:1-0.35:1, or 0.30:1-0.45:1).

[0078] In some embodiments, the aluminum alloy includes specific amounts of total concentrations of Si, Mn, and Fe that satisfy the following formula: Si+Mn-(Fe / 2)≧0.6 (Equation 1) In some embodiments, the aluminum alloy has a value according to Equation 1 of 0.60 to 1.20 (e.g., 0.65 to 1.15, 0.70 to 1.10, 0.70 to 1.05, 0.75 to 1.00, 0.80 to 1.00, 0.85 to 1.00, or 0.90 to 1.00). For example, the values ​​for aluminum alloys according to Eq. 1 are 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, 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, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150 It can be 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, 1.16, 1.17, 1.18, 1.19, or 1.20.

[0079] In certain embodiments, instead of a high excess Si approach, the alloy may use a near-equilibrium to slightly quasi-equilibrium Si approach in the alloy design. In certain embodiments, the excess Si content may be about -1.70 to 0.1. Excess Si, as used herein, is defined by the following equation: Excess Si=(Si)-[(Mg)-0.167(Fe+Mn+Cr)]* *All alloying elements represent the weight % of the alloying element in the aluminum alloy composition. For example, excess Si is approximately -1.70, -1.69, -1.68, -1.67, -1.66, -1.65, -1.64, -1.63, -1.62, -1.61, -1.60, -1.59, -1.58, -1.57, -1.56, -1.55, -1.54, -1.53, -1.52, -1.51, -1.50, -1.49, -1.48, -1.47, -1.46, -1.45, -1.44, -1.43, -1.42, -1.41, -1.40, -1.39, -1.38, -1.37, -1.36, -1.35, -1.34, -1.33, -1.32, -1. 31, -1.30, -1.29, -1.28, -1.27, -1.26, -1.25, -1.24, -1.23, -1.22, -1.21, -1.20, -1.19, -1.18, -1.17, -1.16, -1.15, -1.14, -1.13, -1.12, -1.11, -1 .10, -1.09, -1.08, -1.07, -1.06, -1.05, -1.04, -1.03, -1.02, -1.01, -1.00, -0.99, -0.98, -0.97, -0.96, -0.95, -0.94, -0.93, -0.92, -0.91, -0.90, - 0.89, -0.88, -0.87, -0.86, -0.85, -0.84, -0.83, -0.82, -0.81, -0.80, -0.79, -0.78, -0.77, -0.76, -0.75, -0.74, -0.73, -0.72, -0.71, -0.70, -0.69, -0.68, -0.67, -0.66, -0.65, -0.64, -0.63, -0.62, -0.61, -0.60, -0.59, -0.58, -0.57, -0.56, -0.55, -0.54, -0.53, -0.52, -0.51, -0.50, -0.49, -0.48 ,-0.47,-0.46,-0.45,-0.44,-0.43,-0.42,-0.41,-0.40,-0.39,-0.38,-0.37,-0.36,-0.35,-0.34,-0.33,-0.32,-0.31,-0.30,-0.29,-0.28,-0.2 7, -0.26, -0.25, -0.24, -0.23, -0.22, -0.21, -0.20, -0.19, -0.18, -0.17, -0.16, -0.15, -0.14, -0.13, -0.12, -0.11, -0.10, -0.09, -0.08, -0.07, -0.0.06, -0.05, -0.04, -0.03, -0.02, -0.01, 0, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, or 0.10. In some embodiments, the aluminum alloy has a Cu content of less than about 0.20 wt.%, a Si:Mg ratio of about 0.20:1 to about 0.45:1, and an excess Si content of about -1.30 to 0.

[0080] Properties of the new aluminum alloy The aluminum alloys described herein surprisingly exhibit both high formability and age hardenability. The aluminum alloys described herein also demonstrate good tensile properties, bendability, and deep drawability.

[0081] Additionally, in some embodiments, the aluminum alloys described herein may have a maximum tensile strength (Rm) after batch annealing (e.g., after batch annealing at 330°C for 2 hours) of 120 MPa to about 250 MPa (e.g., about 125 MPa to about 240 MPa, about 130 MPa to about 230 MPa, about 140 MPa to about 220 MPa, or about 150 MPa to about 200 MPa). Additionally, the aluminum alloys described herein may have a Rm after continuous annealing and solution treatment (e.g., CASH at 550°C for 60 seconds) of 180 MPa to 250 MPa (e.g., 185 MPa to 240 MPa, 190 MPa to 235 MPa, 200 MPa to 230 MPa, or 205 MPa to 225 MPa).

[0082] In some embodiments, the aluminum alloys described herein may have a yield strength (Rp0.2) after batch annealing (e.g., after batch annealing at 330°C for 2 hours) of about 40 MPa to about 140 MPa (e.g., about 50 MPa to about 130 MPa, about 60 MPa to about 125 MPa, or about 80 MPa to about 110 MPa). Rp0.2 refers to the amount of stress that results in a plastic strain of 0.2%. Additionally, the aluminum alloys described herein may have an Rp0.2 after continuous annealing and solution treatment (e.g., CASH at 550°C for 0 seconds) of about 80 MPa to about 120 MPa (e.g., about 85 MPa to about 115 MPa, about 90 MPa to about 110 MPa, about 95 MPa to about 110 MPa, or about 95 MPa to about 105 MPa). Additionally, the aluminum alloys described herein may have an Rp0.2 of about 85 MPa to about 125 MPa (e.g., about 90 MPa to about 120 MPa, about 90 MPa to about 115 MPa, about 95 MPa to about 115 MPa, or about 100 MPa to about 115 MPa) after continuous annealing and solution treatment (e.g., CASH at 550°C for 60 seconds).

[0083] In some embodiments, the aluminum alloys described herein may have an Rm after batch annealing (e.g., for a T8x temper, after a batch anneal at 330°C for 2 hours) of about 120 MPa to about 250 MPa (e.g., about 125 MPa to about 240 MPa, about 130 MPa to about 230 MPa, about 140 MPa to about 220 MPa, or about 150 MPa to about 200 MPa). Additionally, the aluminum alloys described herein may have an Rm after continuous annealing and solution treatment (e.g., for a T8x temper, after CASH at 550°C for 0 seconds) of about 160 MPa to about 240 MPa (e.g., about 170 MPa to about 230 MPa, about 175 MPa to about 225 MPa, about 180 MPa to about 225 MPa, or about 190 MPa to about 210 MPa). Additionally, the aluminum alloys described herein may have an Rm after continuous annealing and solution treatment (e.g., CASH at 550° C. for 60 seconds for a T8x temper) of about 180 MPa to about 250 MPa (e.g., about 185 MPa to about 240 MPa, about 190 MPa to about 235 MPa, about 200 MPa to about 230 MPa, or about 205 MPa to about 225 MPa).

[0084] In some embodiments, the aluminum alloys described herein may have an Rp0.2 after batch annealing (e.g., after batch annealing for a T8x temper) of about 50 MPa to about 140 MPa (e.g., about 60 MPa to about 130 MPa, about 70 MPa to about 125 MPa, or about 80 MPa to about 115 MPa). Additionally, the aluminum alloys described herein may have an Rp0.2 after continuous annealing and solution treatment (e.g., CASH at 330° C. for 0 seconds for a T8x temper) of about 80 MPa to about 120 MPa (e.g., about 85 MPa to about 115 MPa, about 90 MPa to about 115 MPa, about 95 MPa to about 110 MPa, or about 95 MPa to about 105 MPa). Additionally, the aluminum alloys described herein may have an Rp of 0.2 after continuous annealing and solution treatment (e.g., CASH at 550° C. for 60 seconds for a T8x temper) of about 90 MPa to about 130 MPa (e.g., about 85 MPa to about 125 MPa, about 90 MPa to about 120 MPa, about 95 MPa to about 115 MPa, or about 100 MPa to about 115 MPa).

[0085] In some aspects, the aluminum alloys described herein may have a yield strength (Rp0.2) of 160 MPa to 250 MPa when tested according to ISO 6892-1 (2016) after a paint bake cycle. For example, the paint cycle may include a 2% prestrain followed by a heat treatment at a temperature of about 185°C for about 20 minutes. In some embodiments, the aluminum alloys described herein may have an Rp0.2 after a paint bake cycle of about 160 MPa to about 250 MPa (e.g., about 180 MPa to about 240 MPa, about 190 MPa to about 235 MPa, about 200 MPa to about 230 MPa, or about 205 MPa to about 225 MPa).

[0086] In some embodiments, the aluminum alloys described herein may have an elongation at break (measured by ISO / EN A80) of at least 15% (e.g., at least 16%, at least 17%, at least 18%, at least 19%, at least 20%, at least 16%, at least 21%, at least 22%, at least 23%, at least 24%, or at least 25%). In terms of ranges, the aluminum alloys may have an elongation of 15% to 30% (e.g., 16% to 28%, 17% to 26%, 18% to 25%, 19% to 24%, 20% to 23%, or 21% to 22.5%).

[0087] In some embodiments, the aluminum alloys described herein may have a uniform elongation (Ag) (measured by ISO / EN Ag) of at least about 15% (e.g., at least about 16%, at least about 17%, at least about 18%, at least about 19%, at least about 20%, at least about 21%, at least about 22%, at least about 23%, at least about 24%, or at least about 25%). In terms of ranges, the aluminum alloys may have an elongation of about 15% to about 25% (e.g., about 16% to about 24%, about 16.5% to about 23%, about 17% to about 22%, about 17% to about 21.5%, about 17.5% to about 21%, about 17.5% to about 20.5%, or about 18% to about 20%).

[0088] In some embodiments, the aluminum alloys described herein have a melting point of at least about 0.40 (e.g., at least about 0.41, at least about 0.42, at least about 0.43, at least about 0.44, at least about 0.45, at least about 0.46, at least about 0.47, at least about 0.48, at least about 0.49, at least about 0.50, at least about 0.51, at least about 0.52, at least about 0.53, at least about 0.54, at least about 0.55, at least about 0.56, at least about 0.57, at least about 0.58, at least about 0.59, at least about 0.60, at least about 0.61 , at least about 0.62, at least about 0.63, at least about 0.64, at least about 0.65, at least about 0.66, at least about 0.67, at least about 0.68, at least about 0.69, at least about 0.70, at least about 0.71, at least about 0.72, at least about 0.73, at least about 0.74, at least about 0.75, at least about 0.76, at least about 0.77, at least about 0.78, at least about 0.79, or at least about 0.80) in any individual direction or all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction). In terms of ranges, the aluminum alloy may have an r (8-12) value of 0.40-0.80 (e.g., 0.42-0.78, 0.45-0.75, 0.46-0.70, 0.50-0.80, 0.52-0.78, 0.55-0.78, 0.56-0.76, 0.60-0.80, 0.62-0.78, 0.64-0.77, 0.66-0.76, or 0.68-0.74) in any individual direction or in all directions (longitudinal (L), diagonal (D), and / or transverse (T) to the rolling direction).

[0089] In some embodiments, the described aluminum alloys have a melting point of at least about 0.40 (e.g., at least about 0.41, at least about 0.42, at least about 0.43, at least about 0.44, at least about 0.45, at least about 0.46, at least about 0.47, at least about 0.48, at least about 0.49, at least about 0.50, at least about 0.51, at least about 0.52, at least about 0.53, at least about 0.54, at least about 0.55, at least about 0.56, at least about 0.57, at least about 0.58, at least about 0.59, at least about 0.60, at least about 0.61, The r(10) value may be at least about 0.62, at least about 0.63, at least about 0.64, at least about 0.65, at least about 0.66, at least about 0.67, at least about 0.68, at least about 0.69, at least about 0.70, at least about 0.71, at least about 0.72, at least about 0.73, at least about 0.74, at least about 0.75, at least about 0.76, at least about 0.77, at least about 0.78, at least about 0.79, or at least about 0.80) in any individual direction or all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction). The r value measured at a strain rate of 10% is designated as r(10). In terms of ranges, the aluminum alloy may have an r(10) value of about 0.40 to about 0.80 (e.g., 0.42 to 0.78, 0.45 to 0.75, 0.46 to 0.70, 0.50 to 0.80, 0.52 to 0.78, 0.55 to 0.78, 0.56 to 0.76, 0.60 to 0.80, about 0.62 to about 0.78, about 0.64 to about 0.77, about 0.66 to about 0.76, or about 0.68 to about 0.74) in any or all directions (longitudinal (L), diagonal (D), and / or transverse (T) to the rolling direction).

[0090] In some embodiments, the described aluminum alloys may have an n(10-20) value of at least about 0.16 (e.g., at least about 0.17, at least about 0.18, at least about 0.19, at least about 0.20, at least about 0.21, at least about 0.22, at least about 0.23, at least about 0.24, at least about 0.25, at least about 0.26, at least about 0.27, at least about 0.28, at least about 0.29, or at least about 0.30) in any or all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction). In terms of ranges, the aluminum alloy may have an n(10-20) value of about 0.16 to about 0.30 (e.g., about 0.17 to about 0.28, about 0.18 to about 0.26, about 0.20 to about 0.26, or about 0.20 to about 0.25) in any individual direction or in all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction).

[0091] In some embodiments, the described aluminum alloys may have an n(10-15) value of at least about 0.16 (e.g., at least about 0.17, at least about 0.18, at least about 0.19, at least about 0.20, at least about 0.21, at least about 0.22, at least about 0.23, at least about 0.24, at least about 0.25, at least about 0.26, at least about 0.27, at least about 0.28, at least about 0.29, or at least about 0.30) in any or all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction). In terms of ranges, the aluminum alloy may have an n(10-20) value of about 0.16 to about 0.30 (e.g., about 0.17 to about 0.28, about 0.18 to about 0.26, about 0.20 to about 0.26, or about 0.20 to about 0.25) in any individual direction or in all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction).

[0092] Aluminum alloy products and methods of using clad aluminum alloy products The aluminum alloy produced from the recycled alloy content can be used to cast various metal casting products, such as billets, ingots, or strips. Methods for producing aluminum sheets are also described herein. The aluminum alloy can be cast, after which further processing steps can be performed. In some examples, the processing steps include casting, preheating and / or homogenization, one or more hot rolling steps, one or more cold rolling steps, solution heat treatment, preaging, and artificial aging.

[0093] The aluminum alloy products described herein can be cast using a direct chill (DC) process or a continuous casting (CC) process. The DC casting process is performed according to standards commonly used in the aluminum industry known to those skilled in the art. The continuous casting system may include a pair of moving opposing casting surfaces (e.g., moving opposing belts, rolls or blocks), a casting cavity between the pair of moving opposing casting surfaces, and a molten metal injector. The molten metal injector may have an end opening through which molten metal may exit the molten metal injector and be injected into the casting cavity.

[0094] Cast aluminum alloy products may be processed by means well known to those skilled in the art. Optionally, the cast aluminum alloy product may be processed using processing steps described herein and used to prepare a sheet, plate or shade. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and an optional pre-aging step, as known to those skilled in the art.

[0095] In the homogenization process, the cast product 207 described herein may be heated to a temperature ranging from, for example, about 400° C. to about 600° C. For example, the cast product may be heated to a temperature 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.

[0096] The product is then soaked (i.e., held at a prescribed temperature) for a period of time. In some examples, the total time in the homogenization process, including the heating and soaking steps, can be up to 20 hours. For example, the homogenization process can include heating the product to about 550° C. and soaking the product for a total time of up to about 10 hours. In some cases, the homogenization process includes multiple treatments. In some non-limiting examples, the homogenization process includes heating the product to a first temperature for a first period of time, followed by heating to a second temperature for a second period of time.

[0097] Following the homogenization step, a hot rolling step may be performed. Prior to the start of hot rolling, the homogenized product may be cooled to a desired temperature, for example, from about 200°C to about 425°C. For example, the homogenized product may be cooled to a temperature of about 200°C to about 400°C, or 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 may then be hot rolled at a hot rolling temperature, such as, for example, 200° C. to 450° C., to produce a hot rolled intermediate product (e.g., hot rolled plate, hot rolled shade, or hot rolled sheet) having a gauge of 3 mm to 100 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, or anything in between). For example, the homogenized product may be hot rolled from an initial gauge of 65 mm to an intermediate gauge of 9.5 mm.

[0098] During hot rolling, the temperature and other operating parameters can be controlled such that the temperature of the hot rolled intermediate product immediately upon exiting the hot rolling mill is less than about 400° C. For example, the temperature of the hot rolled intermediate product upon exiting the hot rolling mill can be less than about 390° C., less than about 380° C., less than about 370° C., less than about 360° C., less than about 350° C., less than about 340° C., less than about 330° C., less than about 325° C., less than about 320° C., less than about 310° C., less than about 300° C., less than about 290° C., less than about 280° C., less than about 270° C., less than about 260° C., or less than about 250° C. The exit temperature of the hot rolled intermediate product from the hot rolling process can control the microstructure of the aluminum alloy. In particular, aluminum alloys produced from high content recycled scrap require tightly controlled heating rates, temperatures, and other operating parameters during the hot rolling process to produce aluminum alloy products with the mechanical properties described herein. The hot rolled intermediate product can then be coil cooled in a furnace. In some embodiments, the hot rolled intermediate product is coil cooled to a temperature of about 10°C to about 100°C. For example, the temperature of the hot rolled intermediate product upon exiting the hot rolling mill can be coil cooled to a temperature of about 10°C, about 20°C, about 25°C, about 30°C, about 40°C, about 50°C, about 60°C, about 70°C, about 80°C, about 90°C, or about 100°C. The total time for coil cooling is up to about 30 hours. In some embodiments, the hot rolled intermediate product is coil cooled to a temperature of about 24°C for about 24 hours.

[0099] The intermediate product, whether cast, homogenized, or hot rolled, can be cold rolled using a cold rolling mill into a thinner product, such as a cold rolled sheet. The cold rolled product may have a gauge of between about 0.5 and 10 mm, for example, between about 0.7 and 6.5 mm. In some cases, the cold rolled product may have a gauge of about 0.5 mm, about 1.0 mm, about 1.5 mm, about 2.0 mm, about 2.5 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 5.0 mm, about 5.5 mm, about 6.0 mm, about 6.5 mm, about 7.0 mm, about 7.5 mm, about 8.0 mm, about 8.5 mm, about 9.0 mm, about 9.5 mm, or about 10.0 mm. Cold rolling may be performed to provide a final gauge thickness that represents a gauge reduction of up to about 85% (e.g., a reduction of up to about 10%, up to about 20%, up to about 30%, up to about 40%, up to about 50%, up to about 60%, up to about 70%, up to about 80%, or up to about 85%) compared to the gauge before the cold rolling began. 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 inter-annealing step (e.g., between one or more cold rolling steps).

[0100] Subsequently, the cast, homogenized, or rolled product may optionally undergo one or more solution heat treatment steps. The clad plate, sheet, or sheet may be heated to a peak metal temperature (PMT) of up to about 600°C (e.g., about 400°C to about 600°C) and soaked at that temperature for a period of time. In some cases, the hot rolling temperature may be about 400°C to about 600°C (e.g., about 430°C to about 500°C, about 440°C to about 490°C, about 450°C to about 480°C, or about 460°C to about 475°C). For example, the rolled product may be soaked at a PMT (e.g., about 550°C) for a soak time of up to 10 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 2 minutes, 3 minutes, 4 minutes, or 5 minutes). In some embodiments, the cast, homogenized, or rolled product can be heated to the peak temperature of the metal in about 10 seconds.

[0101] In some examples, the heating rate of the solution heat treatment step can be about 250° C. / hour to about 350° C. / hour (e.g., about 250° C. / hour, about 255° C. / hour, about 260° C. / hour, about 265° C. / hour, about 270° C. / hour, about 275° C. / hour, about 280° C. / hour, about 285° C. / hour, about 290° C. / hour, about 295° C. / hour, about 300° C. / hour, about 305° C. / hour, about 310° C. / hour, about 315° C. / hour, about 320° C. / hour, about 325° C. / hour, about 330° C. / hour, about 335° C. / hour, about 340° C. / hour, about 345° C. / hour, or about 350° C. / hour).

[0102] Heating rates can be significantly higher, especially for cast, homogenized, or rolled products processed in a continuous solution heat treatment line. Heating rates in a continuous heat treatment line can range from about 5° C. / s to about 20° C. / s (e.g., 5° C. / s, 6° C. / s, 7° C. / s, 8° C. / s, 9° C. / s, 10° C. / s, 11° C. / s, 12° C. / s, 13° C. / s, 14° C. / s, 15° C. / s, 16° C. / s, 17° C. / s, 18° C. / s, 19° C. / s, or 20° C. / s).

[0103] In some embodiments, after solution heat treatment, the hot product can be rapidly cooled (e.g., water quenched). For example, the hot product can be cooled at a rate of greater than 50° C. / second (° C. / sec) to a temperature of about 500° C. to about 200° C. In one example, a clad plate, sheet, or sheet is cooled to a temperature of about 450° C. to about 200° C. at a quench rate of greater than 200° C. / s. In other cases, the cooling rate can be faster, if desired.

[0104] After solution heat treatment, the heat treated product may optionally be subjected to a pre-aging treatment by reheating the product before being coiled. Pre-aging may be performed at a temperature of about 70°C to about 125°C for a period of time up to 6 hours. For example, pre-aging may be performed at a temperature of about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, about 100°C, about 105°C, about 110°C, about 115°C, about 120°C, or about 125°C. Optionally, pre-aging may be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. Pre-aging may be performed by passing the plate, shade, or sheet through a heating device, such as a device that emits radiant heat, convective heat, induction heat, infrared heat, or the like.

[0105] The mechanical properties of the aluminum alloys disclosed herein may be controlled by various aging treatment conditions depending on the desired application. In some cases, the aluminum alloy products described herein can be delivered to customers in Tx tempers (e.g., T1, T4, T5, T6, T7, T8x (e.g., T81 or T82)), W, O, or F tempers. In some examples, an artificial aging step can be performed. The artificial aging step develops the high strength properties of the alloy and optimizes other desirable properties of the alloy. The artificial aging step can be performed at a suitable temperature, such as about 100°C to about 250°C (e.g., at about 180°C or about 225°C). The aging step can be performed for a period of about 10 minutes to about 36 hours (e.g., about 30 minutes or about 24 hours). In some examples, the artificial aging step can be performed at 180°C for 30 minutes to produce a T81 temper. In some examples, the artificial aging process can be carried out at 185°C for 25 minutes to produce a T81 temper. In some further examples, the artificial aging process can be carried out at 225°C for 30 minutes to produce a T82 temper. In some further examples, the alloy is subjected to a natural aging process. The natural aging process can result in a T4 temper.

[0106] How to use aluminum alloys The aluminum alloy products described herein can be used in transportation applications, such as automotive applications and other aircraft, rail, and other applications. For example, the aluminum alloy products can be used to make automotive structural components, such as outer panels, inner panels, side panels, bumpers, side beams, roof beams, cross beams, pillar reinforcements (such as A-pillars, B-pillars, and C-pillars), inner hoods, outer hoods, or trunk lid panels. The aluminum alloys and methods described herein can also be used in aircraft or rail vehicle applications, for example, to make exterior and interior panels. In some examples, the aluminum alloy products and clad aluminum alloy products can be used in aerospace structural and non-structural components or marine structural or non-structural components.

[0107] The aluminum alloy products and methods described herein can also be used in electronics applications. For example, the aluminum alloy products and methods described herein can be used to make housings for electronic devices, including mobile phones and tablet computers. In some examples, the alloys can be used to make enclosures for the outer casings of mobile phones (e.g., smartphones) and the bottom chassis of tablets.

[0108] The cast products described herein can be used to produce products in plate form or other suitable product form. The products can be produced using techniques known to those skilled in the art. In some instances, the aluminum alloys can be used to produce extrusions. For example, the aluminum alloys described herein can be used to produce extruded aluminum alloy products.

[0109] The aluminum alloy products and clad aluminum alloy products and methods described herein may also be used in other applications, if desired. The aluminum alloy products described herein may be provided as aluminum alloy sheets and / or plates suitable for further processing by an end user. For example, the aluminum alloy sheets or clad aluminum alloy sheets may be further subjected to surface treatments by the end user for use as architectural exterior panels for aesthetic and structural purposes.

[0110] The following examples are useful for further illustrating the present invention, but at the same time do not constitute any limitation thereof.On the contrary, it should be clearly understood that after reading the description of this specification, various embodiments, modifications thereof and equivalents that may suggest themselves to those skilled in the art can be used without departing from the spirit of the present invention.In the studies described in the following examples, conventional procedures were followed unless otherwise stated.Some procedures are described below for illustrative purposes. EXAMPLES

[0111] Example 1: The aluminum alloys were direct chill cast to prepare 65 mm ingots. The aluminum alloy specimens were homogenized by heating at 50°C / hr and holding at 550°C for 10 hours. The specimens were then hot rolled from 65 mm gauge to 9.5 mm gauge at an exit temperature of 350°C. The specimens were cooled to 24°C over 24 hours with a furnace shutoff at 350°C to simulate coil cooling. The specimens were then cold rolled to 6.5 mm gauge. The specimens were then solutionized at 550°C for 60 seconds (with a heating time of 10 seconds to the solution treatment temperature) and the specimens were quenched in water. The specimens were then pre-aged at 90°C for 2 hours. The specimens were then artificially aged to specific temperatures as described below and then tested for mechanical properties as detailed below.

[0112] As shown in Table 9, comparative alloys A and B were prepared as a comparison with example alloys 1-9, which are intended to represent existing technology and are representative of the aluminum alloys described herein. Table 9 shows the recycled scrap content and type for examples 1-9 and comparative alloys A and B. Example alloys 1-3 contain 25 wt.% UBC scrap and 75 wt.% mixed recycled alloys, example alloys 4-6 contain 50 wt.% UBC scrap and 50 wt.% mixed recycled alloys, and example alloys 7-9 contain 75 wt.% UBC scrap and 25 wt.% mixed recycled alloys. Comparative examples A and B did not contain any mixed alloys, and comparative example A had up to 25 wt.% UBC. [Table 9]

[0113] The aluminum alloy compositions of the example alloys 1-9 and the comparative alloys A and B are shown in Table 10. In Table 10, all values ​​are in total weight percent (wt%). The alloys may contain up to 0.15 wt% total impurities, the balance being aluminum. [Table 10]

[0114] Table 11 shows the liquidus, solidus, shell and solvation temperatures of alloys 1-9 of the examples and alloys A and B of the comparative examples. The liquidus temperature is the equilibrium temperature at which the aluminum alloy becomes completely liquid, ending with the solidus or shell temperature at which the aluminum alloy completely solidifies. The solvus temperature is the temperature at which all solid precipitates (such as Mg2Si) dissolve in the aluminum alloy. The shell temperature is the non-equilibrium solidus temperature based on the shell approximation, at which the alloy is predicted to completely solidify. The difference between the shell temperature (non-equilibrium) and the solidus temperature (equilibrium temperature) is called the solidification temperature range, which is the processing window for solution heat treatment in the completely solid state. For better workability, a lower solidification temperature range is more desirable. [Table 11]

[0115] FIG. 1 shows the relationship between the solidus temperature and the amount of different recycled scrap materials used to produce Example Alloys 1-9 and Comparative Alloys A and B. As shown in FIG. 1. As shown in FIG. 1, Examples 1-6 have lower solidus temperatures (e.g., 601°C or less) than Comparative Examples A and B, thus demonstrating better processability of the Example aluminum alloys. Furthermore, Examples 7-9 have solidus temperatures comparable to Comparative Examples A and B. FIG. 2 shows the effect of the amount of recycled scrap material on the solvus temperature and solidus temperature. Specifically, FIG. 2 shows that the solidus temperature generally increases with the amount of UBC scrap, whereas the solidus temperature generally decreases with the amount of 5xxx series aluminum alloys and 6xxx series aluminum alloys from mixed recycled scrap.

[0116] Table 12 shows the ratios of Si:Mg and excess Si content for alloys 1-9 of the examples and alloys A and B of the comparative examples. The ratios of Si:Mg and excess Si content are important parameters for achieving the mechanical properties described herein. In particular, aluminum alloy compositions with Si+Mn-(Fe / 2) values ​​between 0.66 and 1.00 provide high paint bake response (e.g., Rp0.2 after paint bake for about 20 minutes at a temperature of about 185°C, 2% prestrain) and good elongation properties. [Table 12]

[0117] Aluminum alloy properties Tensile tests were conducted on comparative alloy 1 and example alloys 1-6. Figures 3a-c are graphs of the ultimate tensile strength (Rm) and yield strength (Rp0.2) of aluminum samples after batch annealing (e.g., after 2-hour batch annealing at 330°C), continuous annealing at 550°C for 0 seconds and solution heat treatment, and continuous annealing at 550°C for 60 seconds and solution heat treatment, respectively. As shown in Figures 3a-c, example alloys 1-9 show tensile strengths comparable to or higher than comparative alloys A and B. Figure 4c shows that example alloys 4-6 (containing about 50% UBC scrap) have higher yield strengths than comparative alloys A and B, and similar ultimate tensile strengths. Similarly, as shown in Figures 7a-7c, when comparative alloys A and B and example alloys 1-9 are artificially aged to the T8x temper, the high recycle content alloys of examples 1-9 still exhibit yield strengths comparable to comparative alloys A and B when subjected to continuous annealing and solution treatment.

[0118] The formability of the specimens was measured with ISO / EN A80 for elongation at break and ISO / EN Ag for uniform elongation. Figures 4a-c show the A80 and Ag of comparative alloys A and B and example alloys 1-9 after batch annealing (e.g., after 2 hour batch annealing at 330°C), continuous annealing at 550°C for 0 seconds and solution heat treatment, and continuous annealing at 550°C for 60 seconds and solution heat treatment, respectively. As shown in Figures 4a-4c, each of example alloys 1-9 exhibited elongation at break of over 17% and uniform elongation of over 15%. For the batch annealed specimens, the elongation at break and uniform elongation generally decreased with the amount of UBC scrap. However, Figure 4c shows that after continuous annealing and solution heat treatment, the high UBC scrap alloys (e.g., examples 4-9) exhibited elongation at break and uniform elongation comparable to example alloys 1-3 and comparative alloys A and B. Figure 9a-c shows that uniform elongation is, for example, greater than 15% for alloys with about 75% UBC scrap, although in examples where the mixed alloy scrap contains more 6xxx series aluminum alloys, improved elongation may be achieved when processed under tailored batch annealing conditions.

[0119] Tensile tests were also used to measure r and n values ​​for the samples using ISO 10113 (2006) and ISO 10275 (2007). Figures 5a-c show the r and n values ​​of comparative alloys A and B and example alloys 1-9 after batch annealing (e.g., after 2 hour batch annealing at 330°C), continuous annealing at 550°C for 0 seconds and solution heat treatment, and continuous annealing at 550°C for 60 seconds and solution heat treatment, respectively. As is evident from Figures 5a-c, example alloys 1-9 show better r values ​​in the 8%-12% strain range over comparative alloy B. Figure 5c shows that example alloys 1-8 show better r values ​​relative to comparative alloy A when subjected to continuous annealing at 550°C for 60 seconds and solution heat treatment. 10a-c show r-values ​​in the 8%-12% strain range as a function of the amount of UBC. In general, Examples 1-9 exhibited higher r-values ​​than Comparative Example B. This is unexpected given that Examples 1-9 contained high UBC scrap recycle content.

[0120] The bending properties of the specimens were measured using beta bend angle according to specification VDA 238-100, and n values ​​were measured using ISO 10275 (2007) over the strain range of 10%-15%. The results of these tests are shown in Figures 6a-c. Example alloys 1-9 exhibited sufficient bending, comparable to comparative alloy B and slightly worse than comparative example A. Surprisingly, example alloys 4-9 achieved this even with a recycled content of UBC scrap exceeding 50%.

[0121] 8a-c are graphs showing the β-bend angles according to specification VDA 238-100 for comparative alloys A and B and example alloys 1-9 after batch annealing (e.g., after 2 hour batch annealing at 330°C), continuous annealing and solution heat treatment at 550°C for 0 seconds, and continuous annealing and solution heat treatment at 550°C for 60 seconds, respectively. As shown in FIG. 8a, the batch annealing process results in bendability and strength values ​​of examples 1-9 with large variations. However, as shown in FIG. 8b and 8c, after the continuous annealing and solution heat treatment process, examples 1-9 showed bendability and strength values ​​superior to comparative alloys A and B.

[0122] 11 and 12 show the effect of Si+Mn-(Fe / 2) content on the elongation and strength (after paint bake) properties of Examples 1-9 and Comparative Examples A and B. Specifically, the (Fe / 2) content in the Si+Mn-Aluminum alloy composition was investigated to determine the effect of these alloying elements on the properties of the aluminum alloys of Examples 1-9 and Comparative Examples A and B. For example, FIG. 11 is a graph of the uniform elongation (Ag) (measured in %) of Example Alloys 1-9 and Comparative Examples A and B as a function of the Si+Mn-(Fe / 2) content in the aluminum alloy composition, and FIG. 12 is a graph of the yield strength (Rp0.2) of Example Alloys 1-9 and Comparative Examples A and B in the T8x temper (y-axis) as a function of the Si+Mn-(Fe / 2) content in the aluminum alloy composition (e.g., Rp0.2 after 2% pre-strain and heat treatment at a temperature of about 185° C. for about 20 minutes). As shown in Figures 11 and 12, the exemplary alloys having Si+Mn-(Fe / 2) contents between 0.70 wt% and 1.0 wt% (e.g., 0.75 wt% and 0.95 wt%) exhibited high strength after paint baking and also exhibited good elongation properties. For example, example alloy 4 exhibited excellent paint baking strength and elongation values ​​and had a Si+Mn-(Fe / 2) content between 0.70 wt% and 1.0 wt%. It was found that with the same amount of UBC (e.g., wt% of UBC), increasing the amount of Si+Mn-Fe / 2 resulted in higher paint baking strength. For example, as shown in Figure 12, the yield strength after heat treatment produced aluminum alloys with higher service strength after paint baking cycles.

[0123] Example 2: Aluminum alloys from mixed alloy scrap In some embodiments, the aluminum alloys described herein can be produced from various combinations of recycled scrap. Examples of alloy compositions prepared from various recycled scrap sources are shown in Table 13 below. Example alloys 10-44 are new formulations of aluminum alloy compositions produced by combining various ratios of various recycled scrap streams. Example alloys 10-44 were produced by direct cold rolling, hot rolling, cold rolling, and continuous annealing and solution heat treatment. Specifically, the hot rolling conditions were critical to producing Example alloys 10-44. [Table 13-1] [Table 13-2]

[0124] In Table 13, all values ​​are total weight percent (wt%). The alloys may contain up to 0.15 wt% total impurities, the balance being aluminum. The aluminum alloys of Examples 10-44 were produced from different mixed alloy scrap materials. In particular, Examples 10-15 were produced from recycled scrap obtained from EOL aluminum-intensive vehicles (e.g., mixed 5xxx series, 6xxx series, and 7xxx series aluminum alloys from wrought and cast aluminum alloys, extruded aluminum, etc.), Example 16 was produced from mixed automobile scrap, Examples 17 and 18 were produced from mixed automobile scrap and primary aluminum alloys, Example 19 was produced from UBC scrap, mixed automobile scrap, and separated automobile scrap, and Examples 20-26 were produced from twitch and mixed automobile. Scrap, Examples 27-29 were made from UBC scrap and mixed auto scrap, Examples 30-33 were made from UBC scrap, mixed auto scrap, and brazing alloy scrap, Examples 34-38 were made from mixed auto scrap and brazing alloy scrap, Examples 39 and 40 were made from UBC scrap, mixed auto scrap, and twitch, Examples 41-44 were made from brazing alloy scrap, mixed auto scrap, and twitch.

[0125] Example 3: Aluminum alloy samples 45-49 were produced according to the process described in Example 1. Table 14 shows the recycled scrap content and type for Examples 45-49. Example Alloy 45 contained 50 wt.% UBC scrap and 50 wt.% mixed alloy scrap, Example Alloy 46 contained 75 wt.% UBC scrap and 25 wt.% mixed alloy scrap, Example Alloy 47 contained 100 wt.% UBC scrap, Example 48 contained 25 wt.% UBC scrap, 50 wt.% mixed alloy scrap, and 25 wt.% random scrap (e.g., non-automotive scrap), and Example 49 contained 90 wt.% can body stock (CBS) and 5-10 wt.% primary aluminum alloy. [Table 14]

[0126] The aluminum alloy compositions of the example alloys 45-49 are shown in Table 15. In Table 15, all values ​​are in total weight percent (wt%). The alloys may contain up to 0.15 wt% total impurities, the balance being aluminum. [Table 15]

[0127] The aluminum alloy compositions of Examples Alloys 45 and 49 have similar compositions to Examples 4 and 9, respectively, but with higher Cu content. The additional Cu in Examples 45 and 46 increased the strength of the aluminum alloys. For example, FIG. 13 shows that the addition of Cu results in higher yield strengths in T4 and T8x tempers (e.g., Rp0.2, after 2% prestrain at a temperature of about 185°C for about 20 minutes). In fact, Examples 45, 46, and 48 had higher strength values ​​than Comparative Examples A and B, which were not made from mixed alloy scrap. Thus, Examples 45, 46, and 48 can achieve higher strength values ​​while incorporating recycled scrap from multiple different scrap systems. Additionally, Examples 45, 46, and 48 showed paint bake responses comparable to Comparative Example A. Examples 47 and 49, which were made primarily from UBS or UBC, had significantly lower strength values.

[0128] 14 and 15 show the elongation and n-values ​​of Examples 45-49 compared to Comparative Examples A and B. Comparative Example B had the highest elongation to break and uniform elongation. However, Examples 45 and 48 showed comparable elongation values. Overall, Example 48 showed the best combination of properties. Thus, depending on which target properties (e.g., high strength, elongation, etc.) are desired, alloying elements can be added to the aluminum alloys produced from recycled scrap to achieve these properties. For example, as shown by Examples Alloys 45 and 46, additional amounts of Cu can be added to the aluminum alloy composition for higher strength and elongation.

[0129] Example Example 1 is an aluminum alloy containing 0.50 wt% to 3.00 wt% Mg, 0.10 wt% to 3.50 wt% Si, 0.01 wt% to 0.60 wt% Fe, maximum 1.20 wt% Cu, 0.10 wt% to 0.90 wt% Mn, maximum 0.20 wt% Cr, maximum 0.20 wt% Ti, maximum 0.10 wt% V, maximum 1.00 wt% Zn, maximum 0.15 wt% impurities, and Al.

[0130] Example 2 is any of the preceding or following exemplary aluminum alloys, including 1.00 wt%-2.50 wt% Mg, 0.20 wt%-3.00 wt% Si, 0.15 wt%-0.50 wt% Fe, 0.001 wt%-0.90 wt% Cu, 0.20 wt%-0.80 wt% Mn, up to 0.15 wt% Cr, up to 0.10 wt% Ti, up to 0.08 wt% V, 0.001 wt%-0.50 wt% Zn, up to 0.15 wt% impurities, and Al.

[0131] Example 3 is any of the preceding or following exemplary aluminum alloys including 1.40 wt%-2.40 wt% Mg, 0.30 wt%-2.50 wt% Si, 0.20 wt%-0.40 wt% Fe, 0.05 wt%-0.75 wt% Cu, 0.40 wt%-0.70 wt% Mn, up to 0.10 wt% Cr, up to 0.05 wt% Ti, up to 0.05 wt% V, 0.005 wt%-0.40 wt% Zn, up to 0.15 wt% impurities, and Al.

[0132] Example 4 is any of the preceding or succeeding exemplary aluminum alloys comprising 1.00 wt%-3.00 wt% Mg, 0.10 wt%-0.90 wt% Si, 0.01 wt%-0.60 wt% Fe, up to 0.50 wt% Cu, 0.10 wt%-0.90 wt% Mn, up to 0.20 wt% Cr, up to 0.20 wt% Ti, up to 0.10 wt% V, up to 1.00 wt% Zn, up to 0.15 wt% impurities, and Al, where the aluminum alloy comprises up to 100% recycled scrap; and where the recycled scrap comprises at least 25% used beverage can scrap, based on the total weight of the recycled scrap.

[0133] Example 5 is any of the preceding or following exemplary aluminum alloys, including 1.25 wt.%-2.50 wt.% Mg, 0.20 wt.%-0.80 wt.% Si, 0.15 wt.%-0.50 wt.% Fe, 0.01 wt.%-0.30 wt.% Cu, 0.20 wt.%-0.80 wt.% Mn, up to 0.15 wt.% Cr, up to 0.10 wt.% Ti, up to 0.05 wt.% V, up to 0.50 wt.% Zn, up to 0.15 wt.% impurities, and Al.

[0134] Example 6 is any of the preceding or following exemplary aluminum alloys including 1.60 wt%-2.40 wt% Mg, 0.30 wt%-0.60 wt% Si, 0.20 wt%-0.40 wt% Fe, 0.05 wt%-0.20 wt% Cu, 0.40 wt%-0.70 wt% Mn, up to 0.10 wt% Cr, up to 0.05 wt% Ti, up to 0.03 wt% V, up to 0.20 wt% Zn, up to 0.15 wt% impurities, and Al.

[0135] Example 7 is any of the preceding or succeeding exemplary aluminum alloys having a Si:Mg weight percent ratio of 0.05:1 to 0.60:1.

[0136] Example 8 is any of the preceding or subsequent example aluminum alloys in which the aluminum alloy has an excess Si content of from -1.70 to 0.10.

[0137] Example 9 is any of the preceding or succeeding exemplary aluminum alloys, where the aluminum alloy includes a Cu content of less than 0.20 wt. %, a Si:Mg ratio of 0.20:1 to 0.45:1, and an excess Si content of -1.30 to 0.

[0138] Example 10 is any of the preceding or following exemplary aluminum alloys in which the recycled scrap comprises at least 50% post-consumer beverage can scrap, based on the total weight of said recycled scrap.

[0139] Example 11 is any of the preceding or succeeding exemplary aluminum alloys in which the recycled scrap comprises at least 25% mixed alloy scrap.

[0140] Example 12 is any of the preceding or following exemplary aluminum alloys where the mixed alloy scrap includes a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0141] Example 13 is any of the preceding or subsequent exemplary aluminum alloys where the mixed alloy scrap has a ratio of 5xxx series aluminum alloy to 6xxx series aluminum alloy of 1:3 to 3:1.

[0142] Example 14 is any of the preceding or following example aluminum alloys, wherein the mixed alloy scrap includes at least 18.75% by weight of a 5xxx series aluminum alloy, based on the total weight of the recycled scrap.

[0143] Example 15 is any of the preceding or following example aluminum alloys, wherein the mixed alloy scrap includes at least 18.75 weight percent of a 6xxx series aluminum alloy, based on the total weight of the recycled scrap.

[0144] Example 16 is any of the preceding or following exemplary aluminum alloys, wherein the aluminum alloy has a yield strength (Rp0.2) of 160 MPa to 250 MPa when tested in accordance with ISO 6892-1(2016) for the T4 temper, paint baked for about 20 minutes at a temperature of about 185°C, and after a 2% prestrain.

[0145] Example 17 is any of the preceding or succeeding exemplary aluminum alloys, in which the aluminum alloy has an elongation to break of at least 15%.

[0146] Example 18 is any of the preceding or subsequent example aluminum alloys, where the aluminum alloy has an r(10) value of at least 0.40 in all directions (longitudinal (L), diagonal (D), and / or transverse (T) relative to the rolling direction).

[0147] Example 19 is any of the preceding or following exemplary aluminum alloys in which the aluminum alloy has a β bend angle of 40° to 100° for bendability testing according to specification VDA238-100.

[0148] Example 20 is any of the preceding or succeeding exemplary aluminum alloys, excluding the primary aluminum alloy.

[0149] Example 21 is any of the preceding or following exemplary aluminum alloys where the aluminum alloy is a sheet, a plate, an electronic device housing, an automotive structural part, an aerospace structural part, an aerospace nonstructural part, a marine structural part, or a marine nonstructural part.

[0150] Example 22 is any of the preceding or subsequent exemplary aluminum alloys in which the aluminum alloy is produced from a process including homogenization, hot rolling, cold rolling, solution treatment, pre-aging, and artificial aging.

[0151] Example 23 is either the preceding or following example aluminum alloy where the aluminum alloy is cold coiled after hot rolling.

[0152] Example 24 is any of the preceding or subsequent exemplary aluminum alloys in which the aluminum alloy contains at least 75% recycled scrap.

[0153] Example 25 is any of the preceding or following exemplary aluminum alloys, where the aluminum alloy includes recycled scrap from one or more of end of life aluminum articles, mixed automotive scrap, UBC scrap, twitch, and heat exchanger scrap.

[0154] Example 26 is any of the preceding or following exemplary aluminum alloys where recycled scrap includes said end of life aluminum articles, said end of life aluminum articles coming from aluminum intensive vehicles.

[0155] Example 27 is any of the preceding or succeeding exemplary aluminum alloys in which recycled scrap comprises 100% of the scrap derived from end-of-life aluminum products.

[0156] Example 28 is any of the preceding or following exemplary aluminum alloys where the recycled scrap includes heat exchanger scrap and the heat exchanger scrap includes braze alloy scrap.

[0157] Example 29 is any of the preceding or following exemplary aluminum alloys where the recycled scrap includes mixed automotive scrap, where the mixed automotive scrap includes recycled scrap from wrought and cast alloys.

[0158] Example 30 is any of the preceding or succeeding exemplary aluminum alloys, where the aluminum alloy comprises up to 25% of the primary aluminum alloy.

[0159] All patents, publications, and abstracts cited above are incorporated herein by reference in their entirety. Various embodiments of the invention are described in accomplishment of the various objects of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the invention. Numerous modifications and adaptations will be readily apparent to those skilled in the art without departing from the spirit and scope of the invention as defined in the following claims.

Claims

1. A method for producing an aluminum alloy using recycled scrap as an aluminum material, comprising: The manufacturing method includes processes including homogenization, hot rolling, cold rolling, solution treatment, pre-aging, and artificial aging; the aluminum alloy is comprised of 1.00 wt% to 2.50 wt% Mg, 0.20 wt% to 3.00 wt% Si, 0.15 wt% to 0.50 wt% Fe, 0.001 wt% to 0.90 wt% Cu, 0.20 wt% to 0.80 wt% Mn, max 0.15 wt% Cr, max 0.10 wt% Ti, max 0.08 wt% V, 0.001 wt% to 0.50 wt% Zn, max 0.15 wt% impurities, and Al; the aluminum alloy having a ratio of Si:Mg by weight from 0.05:1 to 0.60:1 and Si+Mn-(Fe / 2) from 0.60 to 1.20; The method, wherein the aluminum alloy comprises 90% to 100% by weight of a component derived from recycled scrap.

2. The method of manufacturing described in claim 1, wherein the aluminum alloy consists of 1.40 wt% to 2.40 wt% Mg, 0.30 wt% to 2.50 wt% Si, 0.20 wt% to 0.40 wt% Fe, 0.05 wt% to 0.75 wt% Cu, 0.40 wt% to 0.70 wt% Mn, maximum 0.10 wt% Cr, maximum 0.05 wt% Ti, maximum 0.05 wt% V, 0.005 wt% to 0.40 wt% Zn, maximum 0.15 wt% impurities, and Al.

3. A method for manufacturing the aluminum alloy described in claim 1 or 2, wherein the aluminum alloy consists of 1.25 wt% to 2.50 wt% Mg, 0.20 wt% to 0.80 wt% Si, 0.15 wt% to 0.50 wt% Fe, 0.01 wt% to 0.30 wt% Cu, 0.20 wt% to 0.80 wt% Mn, maximum 0.15 wt% Cr, maximum 0.10 wt% Ti, maximum 0.05 wt% V, maximum 0.50 wt% Zn, maximum 0.15 wt% impurities, and Al.

4. A method for manufacturing a aluminum alloy according to any one of claims 1 and 3, wherein the aluminum alloy consists of 1.60% to 2.40% by weight Mg, 0.30% to 0.60% by weight Si, 0.20% to 0.40% by weight Fe, 0.05% to 0.20% by weight Cu, 0.40% to 0.70% by weight Mn, maximum 0.10% by weight Cr, maximum 0.05% by weight Ti, maximum 0.03% by weight V, maximum 0.20% by weight Zn, maximum 0.15% by weight impurities, and Al.

5. The method according to any one of claims 1 to 4, wherein the ratio of Si:Mg by weight is from 0.20:1 to 0.45:

1.

6. The method according to any one of claims 1 to 5, wherein the recycled scrap comprises at least 50% by weight of used beverage can scrap, based on a total weight of the recycled scrap.

7. The method of any one of claims 1 to 6, wherein the recycled scrap comprises at least 25% by weight of mixed alloy scrap.

8. 8. The method of claim 7, wherein the mixed alloy scrap comprises one or more of a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, and a 7xxx series aluminum alloy.

9. 9. The method of claim 8, wherein the ratio of the 5xxx series aluminum alloy to the 6xxx series aluminum alloy in the mixed alloy scrap is from 1:3 to 3:

1.

10. 10. The method of claim 8 or 9, wherein the mixed alloy scrap comprises at least 18.75 wt. % of the 5xxx series aluminum alloy, based on the total weight of the recycled scrap.

11. The method of any one of claims 8 to 10, wherein the mixed alloy scrap comprises at least 18.75 wt.% of the 6xxx series aluminium alloy, based on the total weight of the recycled scrap.

12. 12. The method of any one of claims 1 to 11, wherein the aluminium alloy has a yield strength (Rp0.2) of 160 MPa to 250 MPa for T4 temper, when paint baked at a temperature of about 185°C for about 20 minutes and tested according to ISO 6892-1 (2016) after a 2% pre-strain.

13. The method according to any one of claims 1 to 12, wherein the aluminium alloy has an elongation at break of at least 15%.

14. 14. The method of any one of claims 1 to 13, wherein the aluminium alloy has an r(10) value of at least 0.40 in all directions (longitudinal (L), diagonal (D) and / or transverse (T) relative to the rolling direction).

15. The method of any one of claims 1 to 14, wherein the aluminum alloy has a β-bend angle of 40° to 100° for bendability testing according to specification VDA 238-100.

16. The method of any one of claims 1 to 15, wherein the aluminum alloy is a sheet, a plate, an electronic device housing, an automotive structural part, an aerospace structural part, an aerospace non-structural part, a marine structural part, or a marine non-structural part.

17. The method of claim 1 , wherein the aluminum alloy is cold coiled after hot rolling.

18. The method of any one of claims 1 to 17, wherein the aluminium alloy comprises components derived from recycled scrap from one or more of end of life aluminium articles, mixed automotive scrap, UBC scrap, twitch, and heat exchanger scrap.

19. 20. The method of claim 18, wherein the recycled scrap comprises the end of life aluminum articles, the end of life aluminum articles being derived from aluminum utility vehicles.

20. 20. A method according to claim 18 or 19, wherein the recycled scrap comprises scrap derived from 100% by weight of the end of life aluminium products.

21. The method of any one of claims 18 to 20, wherein the recycled scrap comprises the heat exchanger scrap, and the heat exchanger scrap comprises braze alloy scrap.

22. 22. The method of any one of claims 18 to 21, wherein the recycled scrap comprises mixed automotive scrap, the mixed automotive scrap comprising recycled scrap from wrought and cast alloys.

23. A method according to any one of claims 17 to 19, 21 and 22, wherein the aluminium alloy comprises up to 25% by weight of a primary aluminium alloy.

24. The method of any one of claims 17 to 19, 21 and 22, wherein the aluminum alloy excludes a primary aluminum alloy.

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