Formable corrosion resistant aluminum alloy for structural component

Abstract

Described herein are formable, high strength, and corrosion resistant aluminum alloy compositions and products and methods of preparing and processing the same. The methods of preparing and processing the aluminum alloy products include casting an aluminum alloy and performing tailored rolling and downstream thermal processing steps. The resulting aluminum alloy compositions and products possess high strength and formability properties while also showing resistance to corrosion.

Description

PRIORITY CLAIM

[0001] This application claims priority to U.S. Provisional Application No. 63 / 385,865, filed on Dec. 2, 2022, the entire contents and disclosures of which are incorporated by reference herein.FIELD

[0002] This present disclosure relates to the fields of material science, material chemistry, metallurgy, aluminum alloys, aluminum fabrication, and related fields. In particular, the present disclosure provides novel 7xxx series aluminum alloys having high formability and improved corrosion resistance. The disclosure also provides various methods of producing and processing 7xxx series aluminum alloy products.BACKGROUND

[0003] Aluminum alloys with high strength and formability are desirable for improved product performance in many applications, such as automotive and other transportation applications (including, for example and without limitation, trucks, trailers, trains, aerospace applications, and marine applications), and electronic applications among others. In some cases, such alloys should exhibit, among other properties, high strength and high formability (e.g., an ability to be formed into a desired shape). For example, 7xxx series aluminum alloys have been widely used for such applications due to their improved combination of properties including strength and formability and their ability to be heat treated to increase such properties. Because aluminum alloys are generally 2.8 times less dense than steel, the use of such materials reduces the weight of the vehicle and allows for substantial improvements in its fuel economy. Even so, the use of currently available aluminum alloys in automotive applications poses certain challenges.

[0004] 7xxx series aluminum alloys with low copper (Cu) content (e.g., less than 0.50 wt. % Cu), are susceptible to stress corrosion cracking (SCC). This likely happens as the MgZn2 phase is highly anodic with respect to the aluminum matrix, thus creating space within the microstructure to allow environmental factors to greatly impact the aluminum alloy. Cu may act as a cathodic element in the microstructure; thus, the difference between particles and matrix decreases. Therefore, low Cu-containing 7xxx series alloys may be more susceptible to SCC.SUMMARY

[0005] Covered embodiments of the present disclosure are defined by the claims, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings and each claim.

[0006] Described herein are novel aluminum alloy compositions and methods of producing a formable, high strength, and corrosion resistant aluminum alloy product, comprising casting a molten aluminum alloy to form an ingot or a slab, hot rolling the ingot or the slab to produce a sheet, subjecting the sheet to a solutionizing heat treatment to form a solutionized sheet, pre-aging the solutionized sheet to form a pre-aged sheet, and subjecting the pre-aged sheet to at least one paint bake heat treatment to form the aluminum alloy product, wherein the aluminum alloy comprises Mg and Cu, and wherein the aluminum alloy product has a service strength of at least 370 MPa. In some embodiments, the homogenization and cold rolling are optionally performed, for example, the method may include casting, hot rolling, solutionizing heat treatment, pre-aging, followed by aging. In some embodiments, the method may include the steps of casting, hot rolling, cold rolling, solutionizing heat treatment, pre-aging, and aging. In some embodiments, the method may include casting, homogenization, hot rolling, solutionizing heat treatment, pre-aging, and aging. In some embodiments, the method may include the steps of casting, homogenization, hot rolling, cold rolling, solutionizing heat treatment, pre-aging, and aging. In some embodiments, the pre-aging is conducted at a temperature from 50 to 200° C. for a period of time of from 1 to 24 hours. In some embodiments, the sheet may be cold rolled prior to the solutionizing. In some embodiments, the homogenizing comprises heating the ingot or slab to a temperature of at least 450° C. and maintaining the ingot or slab at the temperature of at least 450° C. for a time of at least 90 minutes. In some embodiments, the ingot or slab may be hot rolled to a thickness of less than 7 mm and cold rolled to a thickness of less than 4 mm. In some embodiments, the method may include further steps, such as artificially aging the pre-aged sheet prior to at least one paint bake treatment. In some embodiments, the artificial aging may be performed at a temperature from 80 to 250° C. for a time period of from 30 minutes to 72 hours. In some embodiments, the method and composition may include preparing an aluminum alloy product. The aluminum alloy product may have an ultimate tensile strength of at least 420 MPa following a 40 day immersion test according to SCC-ASTM G47.

[0007] In some embodiments, the aluminum alloy comprises 0 to 0.25 wt. % Si, 0 to 0.40 wt. % Fe, 0.0 to 0.40 wt. % Cu, 0.0 to 0.30 wt. % Mn, 0.0 to 3.6 wt. % Mg, 0.0 to 0.10 wt. % Cr, 0.0 to 4.5 wt. % Zn, 0.0 to 0.10 wt. % Ti, 0.0 to 0.20 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in an amount of less than 3.6 wt. %. In some embodiments, the aluminum alloy comprises 0 to 0.25 wt. % Si, 0.0 to 0.40 wt. % Fe, 0.0 to 0.40 wt. % Cu, 0.10 to 0.30 wt. % Mn, 2.3 to 3.6 wt. % Mg, 0.0 to 0.10 wt. % Cr, 3.5 to 4.5 wt. % Zn, 0.0 to 0.10 wt. % Ti, 0.0 to 0.20 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %. In some embodiments, the aluminum alloy comprises 0 to 0.25 wt. % Si, 0.0 to 0.40 wt. % Fe, 0.11 to 0.40 wt. % Cu, 0.10 to 0.30 wt. % Mn, 2.3 to 3.6 wt. % Mg, 0.0 to 0.10 wt. % Cr, 3.5 to 4.5 wt. % Zn, 0.0 to 0.10 wt. % Ti, 0.0 to 0.20 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %. In some embodiments, the aluminum alloy comprises 0 to 0.25 wt. % Si, 0.0 to 0.40 wt. % Fe, 0.0 to 0.40 wt. % Cu, 0.10 to 0.30 wt. % Mn, 2.3 to 3.6 wt. % Mg, 0.0 to 0.10 wt. % Cr, 3.5 to 4.5 wt. % Zn, 0.0 to 0.10 wt. % Ti, 0.05 to 0.20 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

[0008] In some embodiments, the method may comprise at least one paint bake treatment, e.g., at least two paint bake treatments. In some embodiments, the method may include the at least one paint bake, wherein the at least one paint bake is conducted at a temperature from 75 to 250° C. for a period of from 15 minutes to 3 hours. In some embodiments, the method may include the at least one paint bake, wherein the at least one paint bake is conducted at a temperature from 100 to 200° C. for a period of from 15 minutes to 2 hours. In some embodiments, the method may include the at least one paint bake, wherein the at least one paint bake is conducted at a temperature from 150 to 180° C. for a period of from 15 minutes to 45 minutes.

[0009] In some embodiments, the aluminum alloy product is formable at room temperature. In some embodiments, the aluminum alloy product is formable at temperatures below room temperature. In some embodiments, the aluminum alloy product has a service strength of at least 390 MPa in T4 temper after at least two paint bake cycles. In some embodiments, the aluminum alloy product has a service strength of at least 400 MPa in T6 temper after at least two paint bake cycles.

[0010] Further aspects, objects, and advantages will become apparent upon consideration of the detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIGS. 1A-1C provide graphs of the yield strength, ultimate tensile strength and total elongation of an aluminum alloy composition described herein at 2.0 mm water quenched (WQ) (1A), 2.4 mm (AQ) (1B), and 2.4 mm WQ (1C) during natural aging response, according to some embodiments described herein.

[0012] FIGS. 2A-2B provide graphs of the yield strength, ultimate tensile strength and total elongation of an aluminum alloy composition described herein after multiple paint bake cycles and T4 temper (2A) or T6 temper (2B) conditions, according to some embodiments described herein.

[0013] FIG. 3 provides a graph of wrap bend for example aluminum alloy described herein after T4 and T6 tempers compared to comparative example 1, according to some embodiments described herein.

[0014] FIGS. 4A-4B provide photographs (4A) and die depths (4B) of various rivets and die designs in an aluminum alloy described herein, according to some embodiments described herein.

[0015] FIG. 5 provides photographs of 2.0 mm WQ, 2.4 mm AC, and 2.4 mm WQ aluminum alloys under 30 kA and 34 Ka, according to some embodiments described herein.

[0016] FIGS. 6A-6B provide a graph (6A) of the forming depth of the swift cup draw test and resulting values (6B) of example 1 and comparative example 3 aluminum alloys as described herein, according to some embodiments described herein.

[0017] FIGS. 7A-7B provide a graph (7A) of the forming depth of the round cup draw test and resulting values (7B) of example 1 and comparative example 3 aluminum alloys as described herein, according to some embodiments described herein.

[0018] FIG. 8 provides a graph of the minor strain vs major strain for comparative examples 1-3 and example 1 aluminum alloys described herein, according to some embodiments described herein.

[0019] FIGS. 9A-9B provide a graph of the stress vs strain for comparative examples 1-3 and example 1 (9A) and photographs of the formability of comparative examples 1-3 and example 1 (9B), according to some embodiments described herein.

[0020] FIG. 10 provides an illustration of the springback section for comparative examples 1-3 and example 1, according to some embodiments described herein.

[0021] FIGS. 11A-11C provide a graph of the maximum intergranular corrosion (IGC) of the aluminum alloy after 24 and 48 hours (11A) and microscopy images of pitting for 2.4 mm WQ T4+PB (11B) and 2.4 mm AQ T4+PB (11C), according to some embodiments described herein.

[0022] FIG. 12 provides microscopy images of the exfoliation testing of an example aluminum alloy, according to some embodiments described herein.

[0023] FIGS. 13A-13C provide a graph of the maximum tensile stress (13A), maximum axial strain (13B), and resulting data (13C), according to some embodiments described herein.

[0024] FIG. 14 provides scanning transition electron microscopy (STEM) images of an aluminum alloy composition described herein, according to some embodiments described herein.DETAILED DESCRIPTION

[0025] Described herein are novel 7xxx series aluminum alloys which exhibit high corrosion resistance while maintaining high strength to weight ratio, formability, and weldability. Among other things, including minor alloying element (zirconium (Zr)) and major components (e.g., copper (Cu) and (magnesium (Mg)) improves the corrosion resistance and reduces the stress corrosion cracking of products formed from the aluminum alloy without causing a substantial loss in strength or formability. Without being bound to any particular theory, it is believed that including Cu, Mg, and minor element Zr, leads to the formation of a larger number of nucleation sites within the microstructure, thus reducing the intergranular corrosion and stress corrosion cracking of the aluminum alloy.

[0026] Aluminum alloys exhibit good uniform corrosion resistance due to the presence of a passive film (e.g., a few nanometers thick) naturally formed by oxidation by air. The passive film, however, can be readily broken down at the local sites when exposed to aggressive environments (e.g., chloride-containing electrolytes), resulting in localized corrosion. In particular, low Cu-containing 7xxx series aluminum alloys are susceptible to SCC in aggressive environments. For some 7xxx series aluminum alloys, heat treating and tempering improves SCC resistance.

[0027] The novel 7xxx series aluminum alloys described herein include higher amounts of Cu and Mg and minor element Zr to improve the SCC resistance while maintaining high strength and formability. 7xxx series aluminum alloys that include higher amounts of major elements Cu and Mg (e.g., 0.10 to 0.40 wt. % and greater than 2.0 wt. %, respectively) and minor element Zr (e.g., 0.01 to 0.20 wt. %) greatly improved SCC resistance as described herein. Additionally described herein are improved methods of generating high strength aluminum alloys. For example, the natural aging of the aluminum alloys described herein may be improved via the incorporation of Zr in amounts from 0.01 wt. % to 0.20 wt. %. In fact, 7xxx series aluminum alloys having Zr, and increased levels of Cu and Mg improved the room temperature formability and reduced the SCC of the alloy when compared to traditional 7xxx series alloys. The 7xxx series aluminum alloys described herein exhibit reduced segregation at the grain boundary as a result of the incorporation of higher levels of Cu, Mg, and Zr, which synergistically reduces the intergranular corrosion and improves the resistance to SCC, thus improving the strength and room temperature formability of the aluminum alloy.Definitions and Descriptions

[0028] The terms “invention,”“the invention,”“this invention,” and “the present invention” used herein are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0029] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “7xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “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.

[0030] The following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %, or %) based on the total weight of the alloy. In certain examples of each alloy, the remainder of the composition is aluminum, with a maximum wt. % of 0.15% for the sum of the impurities. The wt. % of the aluminum alloys adds up to 100 wt. % total and may include Al in an amount to total to 100 wt. %.

[0031] As used herein, the meaning of “a,”“an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0032] As used herein, a plate generally has a thickness of greater than 15 mm up to 200 mm. For example, a plate may refer to an aluminum alloy 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, greater than 100 mm, or up to 200 mm.

[0033] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from 4 mm to 15 mm. For example, a shate 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.

[0034] As used herein, a sheet generally refers to an aluminum product having a thickness of less than 4 mm (e.g., less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm). For example, a sheet may have a thickness of 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5, 0.6 mm 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm 2.7 mm, 2.8 mm, 2.9 mm, 3 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, or 4 mm.

[0035] As used herein, formability refers to the ability of a material to undergo deformation into a desired shape without fracturing, tearing-off, necking, earing, or shaping errors such as wrinkling, spring-back, or galling occurring. In engineering, formability may be classified according to deformation modes. Examples of deformation modes include drawing, stretching, bending, and stretch-flanging.

[0036] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0037] As used herein, terms such as “cast metal product,”“cast product,”“cast aluminum alloy product,” and the like are interchangeable and refer to a product 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, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0038] As used herein, the meaning of “room temperature” can include a temperature of from 15° C. to 30° C., for example 15° C., 16° C., 17° C., 18° C., 19° C., 20° C., 21° C., 22° C., 23° C., 24° C., 25° C., 26° C., 27° C., 28° C., 29° C., or 30° C.

[0039] All ranges disclosed herein are to be understood to encompass any endpoints, and any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, 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.Alloy Compositions

[0040] Aluminum alloy properties are partially determined by the composition of the aluminum alloys. In certain aspects, the alloy composition may influence or even determine whether the alloy will have properties adequate for a desired application.

[0041] The alloy and product described herein are novel aluminum compositions. The aluminum compositions exhibit desirable mechanical and physical properties, such as formability, strength, and a refined microstructure. The properties of the composition are achieved at least in part due to the elemental composition of the aluminum.

[0042] In some examples, an aluminum alloy as described herein may have the following elemental composition as provided in Table 1.TABLE 1ElementWeight Percentage (wt. %)Si0.00-0.25Fe0.00-0.40Cu0.00-0.40Mn0.00-0.30Mg0.00-3.60Cr0.00-0.10Zr0.00-0.20Ti0.00-0.10Zn0.00-4.5 Others0-0.05 (each)0-0.15 (total)Al

[0043] In some examples, the aluminum alloy as described herein may have the following elemental composition as provided in Table 2.TABLE 2ElementWeight Percentage (wt. %)Si0.00-0.25Fe0.00-0.40Cu0.00-0.40Mn0.10-0.30Mg2.30-3.60Cr0.00-0.10Zr0.00-0.20Ti0.00-0.10Zn3.50-4.50Others0-0.05 (each)0-0.15 (total)Al

[0044] In some examples, the aluminum alloy as described herein may have the following elemental composition as provided in Table 3.TABLE 3ElementWeight Percentage (wt. %)Si0.00-0.25Fe0.00-0.40Cu0.11-0.40Mn0.10-0.30Mg2.30-3.60Cr0.00-0.10Zr0.00-0.20Ti0.00-0.10Zn3.50-4.50Others0-0.05 (each)0-0.15 (total)Al

[0045] In some examples, the aluminum alloy as described herein may have the following elemental composition as provided in Table 4.TABLE 4ElementWeight Percentage (wt. %)Si0.00-0.25Fe0.00-0.40Cu0.00-0.40Mn0.10-0.30Mg2.30-3.60Cr0.00-0.10Zr0.05-0.20Ti0.00-0.10Zn3.50-4.50Others0-0.05 (each)0-0.15 (total)AlSilicon (Si)

[0046] In some examples, the aluminum alloy described herein includes Si in an amount of from up to 0.25%, e.g., from 0.00% to 0.25%, from 0.01% to 0.25. %, from 0.05% to 0.25%, from 0.00% to 0.15%, or from 0.00% to 0.20%, based on the total weight of the alloy. For example, the alloy can include 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%, or from 0.25% Si. In some cases, Si is not present in the alloy (i.e., 0%). All expressed in wt. %.Iron (Fe)

[0047] In some examples, the aluminum alloy described herein also includes Fe in an amount of up to 0.40%, e.g., from 0.00% to 0.40%, from 0.10% to 0.40%, from 0.00% to 0.30%, or from 0.10% to 0.40%, based on the total weight of the alloy. For example, the alloy can include 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%, or 0.40% Fe. In some cases, Fe is not present in the alloy (i.e., 0%). All expressed in wt. %.Copper (Cu)

[0048] In some examples, the aluminum alloy described herein includes Cu in an amount of up to 0.40%, e.g., from 0.00 to 0.40%, from 0.00% to 0.30%, or from 0.11% to 0.40%, based on the total weight of the alloy. For example, the alloy can include 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%, or 0.40% Cu. In some cases, Cu is not present in the alloy (i.e., 0%). All expressed in wt. %.Manganese (Mn)

[0049] In some examples, the aluminum alloy described herein can include Mn in an amount of up to 0.30%, e.g., from 0.00% to 0.30%, from 0.05% to 0.30%, or from 0.10% to 0.30%, based on the total weight of the alloy. For example, the alloy can include 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%, or 0.30% Mn. In some cases, Mn is not present in the alloy (i.e., 0%). All expressed in wt. %.Magnesium (Mg)

[0050] In some examples, the aluminum alloy described herein can include Mg in an amount of up to 3.60%, e.g., from 0.00% to 3.60%, from 1.00% to 3.60%, from 2.00% to 3.60%, or from 2.30% to 3.60%, based on the total weight of the alloy. For example, the alloy described herein can include Mg in an amount from 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%, 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%, 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%, 3.30%, 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%, 3.50%, 3.51%, 3.52%, 3.53%, 3.54%, 3.55%, 3.56%, 3.57%, 3.58%, 3.59%, or 3.60% Mg. All expressed in wt. %.Chromium (Cr)

[0051] In some examples, the aluminum alloy described herein includes Cr in an amount of up to 0.10%, e.g., from 0.01% to 0.10%, from 0.05% to 0.10%, from 0.01% to 0.05%, or from 0.01% to 0.05%, based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, of 0.10% Cr. In some cases, Cr is not present in the alloy (i.e., 0%). All expressed in wt. %.Zinc (Zn)

[0052] In some examples, the aluminum alloy described herein includes Zn in an amount of up to 4.50%, e.g., from 0.00% to 4.50%, from 0.50% to 4.00%, from 1.50% to 4.50%, from 2.50% to 4.50%, or from 3.50% to 4.50%, based on the total weight of the alloy. For example, the alloy can include 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%, 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%, 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%, 3.30%, 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%, 3.50%, 3.51%, 3.52%, 3.53%, 3.54%, 3.55%, 3.56%, 3.57%, 3.58%, 3.59%, 3.60%, 3.61%, 3.62%, 3.63%, 3.64%, 3.65%, 3.66%, 3.67%, 3.68%, 3.69%, 3.70%, 3.71%, 3.72%, 3.73%, 3.74%, 3.75%, 3.76%, 3.77%, 3.78%, 3.79%, 3.80%, 3.81%, 3.82%, 3.83%, 3.84%, 3.85%, 3.86%, 3.87%, 3.88%, 3.89%, 3.90%, 3.91%, 3.92%, 3.93%, 3.94%, 3.95%, 3.96%, 3.97%, 3.98%, 3.99%, 4.00%, 4.01%, 4.02%, 4.03%, 4.04%, 4.05%, 4.06%, 4.07%, 4.08%, 4.09%, 4.10%, 4.11%, 4.12%, 4.13%, 4.14%, 4.15%, 4.16%, 4.17%, 4.18%, 4.19%, 4.20%, 4.21%, 4.22%, 4.23%, 4.24%, 4.25%, 4.26%, 4.27%, 4.28%, 4.29%, 4.30%, 4.31%, 4.32%, 4.33%, 4.34%, 4.35%, 4.36%, 4.37%, 4.38%, 4.39%, 4.40%, 4.41%, 4.42%, 4.43%, 4.44%, 4.45%, 4.46%, 4.47%, 4.48%, 4.49%, or 4.50% Zn. In some cases, Zn is not present in the alloy (i.e., 0%). All expressed in wt. %.Tin (Titanium)

[0053] In some examples, the aluminum alloy described herein includes Ti in an amount of up to 0.10%, e.g., from 0.00% to 0.10%, from 0.01% to 0.10%, or from 0.05% to 0.10, based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.10% Ti. In some cases, Ti is not present in the alloy (i.e., 0%). All expressed in wt. %.Zirconium (Zr)

[0054] In some examples, the aluminum alloy described herein includes Zr in an amount of up to 0.20%, e.g., from 0.00% to 0.20%, from 0.01% to 0.20%, or from 0.05% to 0.20%, based on the total weight of the alloy. For example, the alloy can include 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% Zr. In some cases, Zr is not present in the alloy (i.e., 0%). All expressed in wt. %.

[0055] In some non-limiting examples, the Cu and Mg, in combination, may increase corrosion resistance exhibited by the aluminum alloy products. In some examples, the combined amount of Cu and Mg present in the composition is from 0.00 wt. % to 3.6 wt. % (e.g., from 1.0 wt. % to 3.0 wt. %, from 1.5 wt. % to 3.6 wt. %, or from 2.30 wt. % to 3.60 wt. %). For example, the combined amount of Cu and Mg can be 0.01 wt. %, 0.02 wt. %, 0.03 wt. %, 0.04 wt. %, 0.05 wt. %, 0.06 wt. %, 0.07 wt. %, 0.08 wt. %, 0.09 wt. %, 0.10 wt. %, 0.11 wt. %, 0.12 wt. %, 0.13 wt. %, 0.14 wt. %, 0.15 wt. %, 0.16 wt. %, 0.17 wt. %, 0.18 wt. %, 0.19 wt. %, 0.20 wt. %, 0.21 wt. %, 0.22 wt. %, 0.23 wt. %, 0.24 wt. %, 0.25 wt. %, 0.26 wt. %, 0.27 wt. %, 0.28 wt. %, 0.29 wt. %, 0.30 wt. %, 0.31 wt. %, 0.32 wt. %, 0.33 wt. %, 0.34 wt. %, 0.35 wt. %, 0.36 wt. %, 0.37 wt. %, 0.38 wt. %, 0.39 wt. %, 0.40 wt. %, 0.41 wt. %, 0.42 wt. %, 0.43 wt. %, 0.44 wt. %, 0.45 wt. %, 0.46 wt. %, 0.47 wt. %, 0.48 wt. %, 0.49 wt. %, 0.50 wt. %, 0.51 wt. %, 0.52 wt. %, 0.53 wt. %, 0.54 wt. %, 0.55 wt. %, 0.56 wt. %, 0.57 wt. %, 0.58 wt. %, 0.59 wt. %, 0.60 wt. %, 0.61 wt. %, 0.62 wt. %, 0.63 wt. %, 0.64 wt. %, 0.65 wt. %, 0.66 wt. %, 0.67 wt. %, 0.68 wt. %, 0.69 wt. %, 0.70 wt. %, 0.71 wt. %, 0.72 wt. %, 0.73 wt. %, 0.74 wt. %, 0.75 wt. %, 0.76 wt. %, 0.77 wt. %, 0.78 wt. %, 0.79 wt. %, 0.80 wt. %, 0.81 wt. %, 0.82 wt. %, 0.83 wt. %, 0.84 wt. %, 0.85 wt. %, 0.86 wt. %, 0.87 wt. %, 0.88 wt. %, 0.89 wt. %, 0.90 wt. %, 0.91 wt. %, 0.92 wt. %, 0.93 wt. %, 0.94 wt. %, 0.95 wt. %, 0.96 wt. %, 0.97 wt. %, 0.98 wt. %, 0.99 wt. %, 1.00 wt. %, 1.01 wt. %, 1.02 wt. %, 1.03 wt. %, 1.04 wt. %, 1.05 wt. %, 1.06 wt. %, 1.07 wt. %, 1.08 wt. %, 1.09 wt. %, 1.10 wt. %, 1.11 wt. %, 1.12 wt. %, 1.13 wt. %, 1.14 wt. %, 1.15 wt. %, 1.16 wt. %, 1.17 wt. %, 1.18 wt. %, 1.19 wt. %, 1.20 wt. %, 1.21 wt. %, 1.22 wt. %, 1.23 wt. %, 1.24 wt. %, 1.25 wt. %, 1.26 wt. %, 1.27 wt. %, 1.28 wt. %, 1.29 wt. %, 1.30 wt. %, 1.31 wt. %, 1.32 wt. %, 1.33 wt. %, 1.34 wt. %, 1.35 wt. %, 1.36 wt. %, 1.37 wt. %, 1.38 wt. %, 1.39 wt. %, 1.40 wt. %, 1.41 wt. %, 1.42 wt. %, 1.43 wt. %, 1.44 wt. %, 1.45 wt. %, 1.46 wt. %, 1.47 wt. %, 1.48 wt. %, 1.49 wt. %, 1.50 wt. %, 1.51 wt. %, 1.52 wt. %, 1.53 wt. %, 1.54 wt. %, 1.55 wt. %, 1.56 wt. %, 1.57 wt. %, 1.58 wt. %, 1.59 wt. %, 1.60 wt. %, 1.61 wt. %, 1.62 wt. %, 1.63 wt. %, 1.64 wt. %, 1.65 wt. %, 1.66 wt. %, 1.67 wt. %, 1.68 wt. %, 1.69 wt. %, 1.70 wt. %, 1.71 wt. %, 1.72 wt. %, 1.73 wt. %, 1.74 wt. %, 1.75 wt. %, 1.76 wt. %, 1.77 wt. %, 1.78 wt. %, 1.79 wt. %, 1.80 wt. %, 1.81 wt. %, 1.82 wt. %, 1.83 wt. %, 1.84 wt. %, 1.85 wt. %, 1.86 wt. %, 1.87 wt. %, 1.88 wt. %, 1.89 wt. %, 1.90 wt. %, 1.91 wt. %, 1.92 wt. %, 1.93 wt. %, 1.94 wt. %, 1.95 wt. %, 1.96 wt. %, 1.97 wt. %, 1.98 wt. %, 1.99 wt. %, 2.00 wt. %, 2.01 wt. %, 2.02 wt. %, 2.03 wt. %, 2.04 wt. %, 2.05 wt. %, 2.06 wt. %, 2.07 wt. %, 2.08 wt. %, 2.09 wt. %, 2.10 wt. %, 2.11 wt. %, 2.12 wt. %, 2.13 wt. %, 2.14 wt. %, 2.15 wt. %, 2.16 wt. %, 2.17 wt. %, 2.18 wt. %, 2.19 wt. %, 2.20 wt. %, 2.21 wt. %, 2.22 wt. %, 2.23 wt. %, 2.24 wt. %, 2.25 wt. %, 2.26 wt. %, 2.27 wt. %, 2.28 wt. %, 2.29 wt. %, 2.30 wt. %, 2.31 wt. %, 2.32 wt. %, 2.33 wt. %, 2.34 wt. %, 2.35 wt. %, 2.36 wt. %, 2.37 wt. %, 2.38 wt. %, 2.39 wt. %, 2.40 wt. %, 2.41 wt. %, 2.42 wt. %, 2.43 wt. %, 2.44 wt. %, 2.45 wt. %, 2.46 wt. %, 2.47 wt. %, 2.48 wt. %, 2.49 wt. %, 2.50 wt. %, 2.51 wt. %, 2.52 wt. %, 2.53 wt. %, 2.54 wt. %, 2.55 wt. %, 2.56 wt. %, 2.57 wt. %, 2.58 wt. %, 2.59 wt. %, 2.60 wt. %, 2.61 wt. %, 2.62 wt. %, 2.63 wt. %, 2.64 wt. %, 2.65 wt. %, 2.66 wt. %, 2.67 wt. %, 2.68 wt. %, 2.69 wt. %, 2.70 wt. %, 2.71 wt. %, 2.72 wt. %, 2.73 wt. %, 2.74 wt. %, 2.75 wt. %, 2.76 wt. %, 2.77 wt. %, 2.78 wt. %, 2.79 wt. %, 2.80 wt. %, 2.81 wt. %, 2.82 wt. %, 2.83 wt. %, 2.84 wt. %, 2.85 wt. %, 2.86 wt. %, 2.87 wt. %, 2.88 wt. %, 2.89 wt. %, 2.90 wt. %, 2.91 wt. %, 2.92 wt. %, 2.93 wt. %, 2.94 wt. %, 2.95 wt. %, 2.96 wt. %, 2.97 wt. %, 2.98 wt. %, 2.99 wt. %, 3.00 wt. %, 3.01 wt. %, 3.02 wt. %, 3.03 wt. %, 3.04 wt. %, 3.05 wt. %, 3.06 wt. %, 3.07 wt. %, 3.08 wt. %, 3.09 wt. %, 3.10 wt. %, 3.11 wt. %, 3.12 wt. %, 3.13 wt. %, 3.14 wt. %, 3.15 wt. %, 3.16 wt. %, 3.17 wt. %, 3.18 wt. %, 3.19 wt. %, 3.20 wt. %, 3.21 wt. %, 3.22 wt. %, 3.23 wt. %, 3.24 wt. %, 3.25 wt. %, 3.26 wt. %, 3.27 wt. %, 3.28 wt. %, 3.29 wt. %, 3.30 wt. %, 3.31 wt. %, 3.32 wt. %, 3.33 wt. %, 3.34 wt. %, 3.35 wt. %, 3.36 wt. %, 3.37 wt. %, 3.38 wt. %, 3.39 wt. %, 3.40 wt. %, 3.41 wt. %, 3.42 wt. %, 3.43 wt. %, 3.44 wt. %, 3.45 wt. %, 3.46 wt. %, 3.47 wt. %, 3.48 wt. %, 3.49 wt. %, 3.50 wt. %, 3.51 wt. %, 3.52 wt. %, 3.53 wt. %, 3.54 wt. %, 3.55 wt. %, 3.56 wt. %, 3.57 wt. %, 3.58 wt. %, 3.59 wt. %, or 3.60 wt. %.

[0056] The presence of Cu in an amount of at least 0.10 wt. %, Mg in an amount of at least 2.8 wt. % and Cu as the predominate alloying element (other than Al), in combination with the processing conditions described below, may result in an aluminum alloy product having exceptional strength and formability. In some cases, the combination results in an aluminum alloy product having high corrosion resistance.Minor Elements

[0057] Optionally, the aluminum alloys described herein can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01% or below. These impurities may include, but are not limited to, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Accordingly, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, or Pb, may be present in alloys in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01% or below. The sum of all impurities does not exceed 0.15% (e.g., 0.1%). All expressed in wt. %. The remaining percentage of each alloy can be aluminum.

[0058] The aluminum alloys described herein can contain at least 40 wt. % recycled content. For example, the aluminum alloys can contain at least 45 wt. %, at least 50 wt. %, at least 60 wt. %, at least 70 wt. %, at least 80 wt. %, at least 90 wt. %, or at least 95 wt. % recycled content.Processing Methods

[0059] Optionally, suitable aluminum alloy products for use in the methods described herein include 7xxx series aluminum alloys. In some cases, a 7xxx series aluminum alloy for use in the methods described herein can be a 7xxx series aluminum alloy as registered with the Aluminum Association, and can optionally be modified to include an amount of Zr, Mg, Zn, and / or any other element as described above. The 7xxx series aluminum alloy can include, for example, AA7003, AA7004, AA7204, AA7005, AA7108, AA7108A, AA7009, AA7010, AA7012, AA7014, AA7015, AA7016, AA7116, AA7017, AA7018, AA7019, AA7019A, AA7020, AA7021, AA7022, AA7122, AA7023, AA7024, AA7025, AA7026, AA7028, AA7029, AA7129, AA7229, AA7030, AA7031, AA7032, AA7033, AA7034, AA7035, AA7035A, AA7036, AA7136, AA7037, AA7039, AA7040, AA7140, AA7041, AA7042, AA7046, AA7046A, AA7047, AA7049, AA7049A, AA7149, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7072, AA7075, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7085, AA7185, AA7090, AA7093, AA7095, AA7099, or AA7199 that has optionally been modified to include at least 0.1 wt. % Zr, at least 2.3 wt. % magnesium (Mg), at least 0.1 wt. % copper (Cu), and zinc (Zn) as a predominate alloying element.

[0060] In some examples, the alloy is a monolithic alloy. In some examples, the alloy is a clad aluminum alloy, having a core layer and one or two cladding layers. In some cases, the core layer may be different from one or both of the cladding layers. The core layer can be, for example, an aluminum alloy as described herein (e.g., an aluminum alloy including at least 0.1 wt. % Zr, at least 2.3 wt. % Mg, at least 0.1 wt. % Cu, and Zn as a predominate alloying element other than Al).Casting

[0061] The alloys can be cast using any suitable casting process. For example, a molten aluminum alloy composition including an aluminum alloy as described herein may be cast using a continuous casting (CC) process that may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters. In some examples, the casting process is performed by a CC process to form a cast product such as a billet, slab, strip, or the like.

[0062] In some cases, the resulting cast aluminum alloy product can exit the caster at a temperature (e.g., a caster exit temperature) of from 370° C. to 450° C. For example, the cast aluminum alloy product can have a caster exit temperature of 370° C., 380° C., 390° C., 400° C., 410° C., 420° C., 430° C., 440° C., 450° C., or anywhere in between.

[0063] The resulting cast aluminum alloy product can have a thickness of 5 mm to 50 mm (e.g., from 10 mm to 45 mm, from 15 mm to 40 mm, or from 20 mm to 35 mm), such as 10 mm. For example, the cast aluminum alloy product can be 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, 41 mm, 42 mm, 43 mm, 44 mm, 45 mm, 46 mm, 47 mm, 48 mm, 49 mm, or 50 mm thick.

[0064] The cast aluminum alloy product can then be subjected to further processing steps. In some non-limiting examples, the processing method includes hot rolling, coiling, coil cooling, further processing, solutionizing, and / or aging. In some cases, the further processing can include homogenizing and hot rolling to a final gauge. In other cases, the further processing steps can include homogenizing, cooling, and cold rolling to a final gauge. In still other cases, the further processing steps can include cold rolling to a final gauge.Hot Rolling

[0065] Following the casting step, a hot rolling step can be performed. In some cases, the hot rolling step can be performed immediately after the casting. The hot rolling step can include a hot reversing mill operation and / or a hot tandem mill operation. The hot rolling step can be performed at a temperature ranging from 250° C. to 500° C. (e.g., from 300° C. to 400° C. or from 350° C. to 430° C.). For example, the hot rolling step can be performed at a temperature of 250° C., 260° C., 270° C., 280° C., 290° C., 300° C., 310° C., 320° C., 330° C., 340° C., 350° C., 360° C., 370° C., 380° C., 390° C., 400° C., 410° C., 420° C., 430° C., 440° C., 450° C., 460° C., 470° C., 480° C., 490° C., 500° C., or anywhere in between.

[0066] In the hot rolling step, the cast aluminum alloy product can be hot rolled to a thickness of 15 mm or less (e.g., from 2 mm to 10 mm), providing an aluminum alloy hot band. For example, the cast aluminum alloy product can be hot rolled to a 15 mm gauge or less, a 14 mm gauge or less, a 13 mm gauge or less, a 12 mm gauge or less, an 11 mm gauge or less, a 10 mm gauge or less, a 9 mm gauge or less, an 8 mm gauge or less, a 7 mm gauge or less, a 6 mm gauge or less, a 5 mm gauge or less, a 4 mm gauge or less, a 3 mm gauge or less, or a 2 mm gauge or less. In some cases, the percentage reduction in thickness resulting from the hot rolling step can be at least 40% (e.g., from 40% to 50%). For example, the thickness of the cast aluminum alloy product can be reduced by 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80%. In some cases, the aluminum alloy hot band can exit the hot reversing mill and / or the hot tandem mill (i.e., hot mill) at a temperature of from 300° C. to 400° C. For example, the aluminum alloy hot band can have a hot mill exit temperature of 300° C., 310° C., 320° C., 330° C., 340° C., 350° C., 360° C., 370° C., 380° C., 390° C., 400° C., or anywhere in between.Coiling and Coil Cooling

[0067] Optionally, the aluminum alloy hot band can be coiled into a hot band coil upon exit from the hot mill. In some further examples, the hot band coil is cooled in air (referred to as a coil cooling). The coil cooling step can be performed at a rate of 12.5° C. / hour (° C. / h) to 3600° C. / h. For example, the coil cooling step can be performed at a rate of 12.5° C. / h, 25° C. / h, 50° C. / h, 100° C. / h, 200° C. / h, 400° C. / h, 800° C. / h, 1600° C. / h, 3200° C. / h, 3600° C. / h, or anywhere in between. The hot band coil can be cooled to a temperature of from 300° C. to 400° C. For example, the hot band coil can be cooled to a temperature of 300° C., 310° C., 320° C., 330° C., 340° C., 350° C., 360° C., 370° C., 380° C., 390° C., or 400° C.

[0068] In some examples, the air cooled coil can be stored for a period of time. For example, the coil can be maintained at a temperature of 300° C. to 400° C. for 1 hour or more (e.g., 2 hours or more, 5 hours or more, 10 hours or more, 1 day or more, 2 days or more, or 1 week or more).Homogenization, Hot Rolling to Final Gauge, Coil Cooling, and Cold Rolling to Final Gauge

[0069] Optionally, a homogenization step can be performed after hot rolling, coiling, and coil cooling. The homogenization step can include heating the hot band coil to attain a peak metal temperature (PMT) of, or at least, 450° C. (e.g., at least 460° C., at least 470° C., at least 480° C., at least 490° C., at least 500° C., at least 510° C., at least 520° C., at least 530° C., at least 540° C., at least 550° C., at least 560° C., at least 570° C., or at least 580° C.). For example, the hot band coil can be heated to a temperature of from 450° C. to 580° C., from 460° C. to 575° C., from 465° C. to 570° C., from 470° C. to 565° C., from 475° C. to 555° C., or from 480° C. to 550° C. In some cases, the heating rate to the PMT can be 100° C. / hour or less, 75° C. / hour or less, 50° C. / hour or less, 40° C. / hour or less, 30° C. / hour or less, 25° C. / hour or less, 20° C. / hour or less, or 15° C. / hour or less. In other cases, the heating rate to the PMT can be from 10° C. / min to 100° C. / min (e.g., from 10° C. / min to 90° C. / min, from 15° C. / min to 70° C. / min, from 20° C. / min to 60° C. / min, from 20° C. / min to 50° C. / min, or from 30° C. / min to 40° C. / min).

[0070] The hot band coil is then allowed to soak (i.e., held at the indicated temperature) for a period of time. According to one non-limiting example, the hot band coil is allowed to soak for up to 36 hours (e.g., for 30 minutes, for 2 hours, or for 36 hours). For example, the hot band coil can be soaked at the indicated temperature for 30 minutes, 60 minutes (i.e., 1 hour), 90 minutes, 120 minutes (i.e., 2 hours), 150 minutes, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours, 26 hours, 27 hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours, 35 hours, 36 hours, or anywhere in between.

[0071] In some non-limiting examples, a homogenization step is not performed.

[0072] Optionally, the homogenized hot band coil can be hot rolled to provide a final gauge aluminum alloy product. The hot rolling to final gauge step can be performed after the homogenization step employing, for example, a finishing mill. The hot rolling step can be performed at a temperature ranging from 250° C. to 500° C. (e.g., from 300° C. to 400° C. or from 350° C. to 430° C.). For example, the hot rolling step can be performed at a temperature of 250° C., 260° C., 270° C., 280° C., 290° C., 300° C., 310° C., 320° C., 330° C., 340° C., 350° C., 360° C., 370° C., 380° C., 390° C., 400° C., 410° C., 420° C., 430° C., 440° C., 450° C., 460° C., 470° C., 480° C., 490° C., 500° C., or anywhere in between.

[0073] The hot rolling to final gauge step can further reduce the thickness of the hot band to a final gauge of from 0.5 mm to 6 mm. For example, the hot rolling to final gauge step can provide an aluminum alloy product having a gauge of 6 mm or less, 5.5 mm or less, 5 mm or less, 4.5 mm or less, 4 mm or less, 3.5 mm or less, 3 mm or less, 2.5 mm or less, 2 mm or less, 1.5 mm or less, 1 mm or less, 0.5 mm, or anywhere in between.

[0074] Optionally, after homogenization, the homogenized hot band coil can undergo coil cooling and cold rolling. The homogenized hot band coil can be cooled in air at a rate of 12.5° C. / hour (° C. / h) to 3600° C. / h. For example, the coil cooling step can be performed at a rate of 12.5° C. / h, 25° C. / h, 50° C. / h, 100° C. / h, 200° C. / h, 400° C. / h, 800° C. / h, 1600° C. / h, 3200° C. / h, 3600° C. / h, or anywhere in between. Following the coil cooling, a cold rolling step can optionally be performed. During the cold rolling step, the homogenized hot band coil can be cold rolled to a thickness of from 0.1 mm to 6 mm (e.g., from 0.5 mm to 5 mm). For example, the homogenized hot band coil can be cold rolled to a thickness of less than 4 mm to provide a final gauge aluminum alloy product. For example, the final gauge aluminum alloy product can have a thickness of 6 mm or less, 5.5 mm or less, 5 mm or less, 4.5 mm or less, 4 mm or less, 3.5 mm or less, 3 mm or less, 2.5 mm or less, 2 mm or less, 1.5 mm or less, 1 mm or less, 0.5 mm, or anywhere in between. Optionally, the cold rolling step can be performed without a homogenization step and / or a hot rolling step.

[0075] In some cases, an exemplary sequence of steps for use in further processing the hot band coil to provide a final gauge aluminum alloy product includes homogenizing the hot band coil to provide a homogenized hot band coil and hot rolling the homogenized hot band coil to provide the final gauge aluminum alloy product. In other cases, an exemplary sequence of steps for use in further processing the hot band coil to provide a final gauge aluminum alloy product includes homogenizing the hot band coil to provide a homogenized hot band coil, cooling the homogenized hot band coil, and cold rolling the homogenized hot band coil to provide a final gauge aluminum alloy product. In still other cases, further processing the hot band coil to provide a final gauge aluminum alloy product includes cold rolling the hot band coil to provide a final gauge aluminum alloy product.Solutionizing

[0076] The methods described herein further include a step of solutionizing the final gauge aluminum alloy product. The solutionizing step can include heating or cooling, as necessary, the final gauge aluminum alloy product to a solutionizing temperature of 450° C. or greater (e.g., from 460° C. to 600° C., from 465° C. to 575° C., from 470° C. to 550° C., from 475° C. to 525° C., or from 480° C. to 500° C.). The final gauge aluminum alloy product can soak at the solutionizing temperature for a period of time. In certain aspects, the final gauge aluminum alloy product is allowed to soak for at least 30 seconds (e.g., from 60 seconds to 120 minutes, inclusively). For example, the final gauge aluminum alloy product can be soaked at the temperature of 450° C. or greater for 30 seconds, 35 seconds, 40 seconds, 45 seconds, 50 seconds, 55 seconds, 60 seconds, 65 seconds, 70 seconds, 75 seconds, 80 seconds, 85 seconds, 90 seconds, 95 seconds, 100 seconds, 105 seconds, 110 seconds, 115 seconds, 120 seconds, 125 seconds, 130 seconds, 135 seconds, 140 seconds, 145 seconds, 150 seconds, 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes, 40 minutes, 45 minutes, 50 minutes, 55 minutes, 60 minutes, 65 minutes, 70 minutes, 75 minutes, 80 minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, 105 minutes, 110 minutes, 115 minutes, or 120 minutes, or anywhere in between. In certain aspects, the solutionizing is performed immediately after a hot rolling step or a cold rolling step.Quenching

[0077] The methods described herein include a quenching step. The term “quenching,” as used herein, can include rapidly reducing a temperature of a final gauge aluminum alloy product that has been solutionized as described above. In the quenching step, the product can be quenched with a liquid (e.g., water), gas (air), any other suitable quench medium, or any combination thereof. In certain aspects, the product can be quenched using water having a water temperature of between 40° C. and 75° C. In certain aspects, the product is quenched using forced air.

[0078] In certain aspects, the product can be cooled to a temperature of 25° C. to 65° C. at a quench speed that can vary between 50° C. / s to 400° C. / s in a quenching step that is based on the selected gauge. For example, the quench rate can be from 50° C. / s to 375° C. / s, from 60° C. / s to 375° C. / s, from 70° C. / s to 350° C. / s, from 80° C. / s to 325° C. / s, from 90° C. / s to 300° C. / s, from 100° C. / s to 275° C. / s, from 125° C. / s to 250° C. / s, from 150° C. / s to 225° C. / s, or from 175° C. / s to 200° C. / s.Pre-Aging

[0079] In some cases, a pre-aging step can be performed. Not to be bound by theory, the pre-aging step can at least partially arrest the mechanical property changes caused by natural aging of the aluminum alloy product. Optionally, the pre-aging step can be performed before the solutionizing step or after the solutionizing step. The pre-aging step can include heating the final gauge aluminum alloy product to a pre-aging temperature of from 50° C. to 300° C. (e.g., from 75° C. to 250° C., from 100° C. to 300° C., from 100° C. to 275° C., or from 100° C. to 250° C.). For example, the pre-aging step can include heating the final gauge aluminum alloy product to a temperature of 50° C., 55° C., 60° C., 65° C., 70° C., 75° C., 80° C., 85° C., 90° C., 95° C., 100° C., 105° C., 110° C., 115° C., 120° C., 125° C., 130° C., 135° C., 140° C., 145° C., 150° C., 155° C., 160° C., 165° C., 170° C., 175° C., 180° C., 185° C., 190° C., 195° C., 200° C., 205° C., 210° C., 215° C., 220° C., 225° C., 230° C., 235° C., 240° C., 245° C., 250° C., 255° C., 260° C., 265° C., 270° C., 275° C., 280° C., 285° C., 290° C., 295° C., 300° C. The final gauge aluminum alloy product can be maintained at the pre-aging temperature for a period of up to 72 hours (e.g., from 1 hour to 72 hours). For example, the final gauge aluminum alloy product can be maintained for 72 hours or less, 60 hours or less, 48 hours or less, 36 hours or less, 24 hours or less, 12 hours or less, 6 hours or less, 5 hours or less, 4 hours or less, 3 hours or less, 2 hours or less, 1 hour or less, or anywhere in between.Aging

[0080] After the solutionizing, quenching and / or pre-aging steps, one or more aging steps can be performed. The aging can include one or more of natural aging, artificial aging, paint baking, and post-forming heat treating.

[0081] Optionally, the aging can include a natural aging step. The natural aging can include a step of maintaining the final gauge aluminum alloy product at room temperature for a period of time. For example, the final gauge aluminum alloy product can be maintained at room temperature for up to 12 weeks (e.g., 1 day, 2 days, 3 days, 4 days, 5 days, 6 days, 1 week, 2 weeks, 3 weeks, 4 weeks, 5 weeks, 6 weeks, 7 weeks, 8 weeks, 9 weeks, 10 weeks, 11 weeks, or 12 weeks).

[0082] Aluminum alloy products prepared according to the methods described herein can be delivered after being subjected to the optional pre-aging and natural aging. The aluminum alloy products can achieve high yield strengths after processing by an end user, for example, by deforming (e.g., stamping, pressing, forming, or any suitable deforming process) and / or by aging or thermal treatment (e.g., coating and paint baking, artificial aging, post-forming heat treatment, or any suitable end user thermal treatment). Optionally, after the optional pre-aging and / or natural aging step, the aluminum alloy products described herein are subjected to, for example, a forming process, a coating process, an artificial aging step, and / or a paint baking process.

[0083] Optionally, the aging can include an artificial aging step. The artificial aging can include heating the final gauge aluminum alloy product to an artificial aging temperature of from 80° C. to 250° C. (e.g., from 80° C. to 225° C., from 100 to 225° C., from 100° C. to 225° C., from 110° C. to 220° C., from 115° C. to 210° C., or from 120° C. to 210° C., from 125° C. to 225° C., from 140° C. to 225° C., from 160° C. to 225° C., from 180° C. to 225° C., from 200° C. to 225° C., and all combinations of endpoints). The artificial aging step can include maintaining the artificial aging temperature for a period of from 30 minutes hours to 72 hours (e.g., 1 hour, 2 hours, 4 hours, 8 hours, 10 hours, 12 hours, 15 hours, 20 hours, 24 hours, 30 hours 48 hours, 60 hours, or 72 hours, including combinations of all endpoints).

[0084] In some aspects, an optional coating procedure can be performed (e.g., painting, electrocoating, or zinc-phosphating, to name a few). After coating, the final gauge aluminum alloy product can be subjected to further thermal treatment including paint baking, post-forming heat treatment, any suitable OEM thermal treatment process, or any combination thereof. The paint bake can further strengthen the aluminum alloy product providing a high strength aluminum alloy product having an optionally complex formed shape. In some cases, a paint baking procedure can include heating the aluminum alloy product to a paint baking temperature of from 75° C. to 250° C. and maintaining the aluminum alloy product at the paint baking temperature for a period of up to 3 hours (e.g., from 15 minutes to 2 hours, from 15 minutes to 45 minutes, or from 30 minutes to 1 hour). In some aspects, the at least one paint baking step may be is conducted at a temperature from 75 to 250° C. for a period of from 15 minutes to 3 hours, at a temperature from 100 to 200° C. for a period of from 15 minutes to 2 hours, or at a temperature from 150 to 180° C. for a period of from 15 minutes to 45 minutes.

[0085] In some further cases, a post-forming heat treatment can be performed. The post-forming heat treatment procedure can include heating the final gauge aluminum alloy product to a post-forming heat treating temperature of from 100° C. to 250° C. and maintaining this temperature for 1 hour to 24 hours (e.g., from 2 hours to 12 hours). In some embodiments, the method of forming the aluminum alloy described herein may comprise at least one paint bake treatment. In some embodiments, the method of making the aluminum alloy described herein may comprise at least 2 paint bake treatments. The method of making the aluminum alloy described herein may comprise from 1 to 5 paint bake treatments. For example, the method of making the aluminum alloy described herein may include 1 paint bake treatment, 2 paint bake treatments, 3 paint bake treatments, 4 paint bake treatments, 5 paint bake treatments, or greater than 5 paint bake treatments.Alloy Product Properties

[0086] The aluminum alloy products described herein can have high strength and formability properties, before and after aging as described herein. In some aspects, the aluminum alloy product is formable at a temperature below room temperature, e.g., from 0 to up to 15° C. In some aspects, the aluminum alloy product is formable at ambient (room) temperature and may be formable at temperatures up to 40° C.

[0087] The aluminum alloy products may, have a service strength (yield strength that goes in service after final heat treatment, including natural and artificial aging) of at least 390 MPa in T4 temper, such as after at least two paint bake cycles, e.g., at least 395 MPa, at least 400 MPa, at least 405 MPa, at least 410 MPa, at least 415 MPa, at least 420 MPa, at least 425 MPa, at least 430 MPa, at least 435 Pa, at least 440 Pa, at least 445 MPa, at least 450 MPa, at least 455 MPa, at least 460 MPa, at least 465 MPa, at least 470 MPa, at least 475 MPa, and up to 500 MPa.

[0088] In some cases, the aluminum alloy product achieves an increase in elongation and an increase in yield strength after aging as compared to an elongation and a yield strength achieved by the aluminum alloy product before aging. The increase in elongation can be at least 1% (e.g., from 1.5% to 5% or from 2% to 3%). For example, the increase in elongation can be 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, or greater than 5%.

[0089] The increase in yield strength can be at least 15 MPa (e.g., from 15 MPa to 150 MPa). For example, the increase in yield strength can be 15 MPa, 16 MPa, 17 MPa, 18 MPa, 19 MPa, 20 MPa, 21 MPa, 22 MPa, 23 MPa, 24 MPa, 25 MPa, 26 MPa, 27 MPa, 28 MPa, 29 MPa, 30 MPa, 31 MPa, 32 MPa, 33 MPa, 34 MPa, 35 MPa, 36 MPa, 37 MPa, 38 MPa, 39 MPa, 40 MPa, 41 MPa, 42 MPa, 43 MPa, 44 MPa, 45 MPa, 46 MPa, 47 MPa, 48 MPa, 49 MPa, 50 MPa, 51 MPa, 52 MPa, 53 MPa, 54 MPa, 55 MPa, 56 MPa, 57 MPa, 58 MPa, 59 MPa, 60 MPa, 61 MPa, 62 MPa, 63 MPa, 64 MPa, 65 MPa, 66 MPa, 67 MPa, 68 MPa, 69 MPa, 70 MPa, 71 MPa, 72 MPa, 73 MPa, 74 MPa, 75 MPa, 76 MPa, 77 MPa, 78 MPa, 79 MPa, 80 MPa, 81 MPa, 82 MPa, 83 MPa, 84 MPa, 85 MPa, 86 MPa, 87 MPa, 88 MPa, 89 MPa, 90 MPa, 91 MPa, 92 MPa, 93 MPa, 94 MPa, 95 MPa, 96 MPa, 97 MPa, 98 MPa, 99 MPa, 100 MPa, 101 MPa, 102 MPa, 103 MPa, 104 MPa, 105 MPa, 106 MPa, 107 MPa, 108 MPa, 109 MPa, 110 MPa, 111 MPa, 112 MPa, 113 MPa, 114 MPa, 115 MPa, 116 MPa, 117 MPa, 118 MPa, 119 MPa, 120 MPa, 121 MPa, 122 MPa, 123 MPa, 124 MPa, 125 MPa, 126 MPa, 127 MPa, 128 MPa, 129 MPa, 130 MPa, 131 MPa, 132 MPa, 133 MPa, 134 MPa, 135 MPa, 136 MPa, 137 MPa, 138 MPa, 139 MPa, 140 MPa, 141 MPa, 142 MPa, 143 MPa, 144 MPa, 145 MPa, 146 MPa, 147 MPa, 148 MPa, 149 MPa, 150 MPa, or greater than 150 MPa.

[0090] In some examples, the aluminum alloy products have a yield strength of greater than 350 MPa after processing according to the methods described herein. For example, the aluminum alloy products can have a yield strength of 360 MPa or greater, 365 MPa or greater, 370 MPa or greater, 375 MPa or greater, 380 MPa or greater, 385 MPa or greater, 390 MPa or greater, 395 MPa or greater, 400 MPa or greater, 405 MPa or greater, 410 MPa or greater, 415 MPa or greater, 420 MPa or greater, 425 MPa or greater, 430 MPa or greater, 435 MPa or greater, 440 MPa or greater, 445 MPa or greater, 450 MPa or greater, 455 MPa or greater, 460 MPa or greater, 465 MPa or greater, 470 MPa or greater, or 475 MPa or greater, 480 MPa or greater, 485 MPa or greater, 490 MPa or greater, 495 MPa or greater, 500 MPa or greater, 505 MPa or greater, 510 MPa or greater, 515 MPa or greater, 520 MPa or greater, 525 MPa or greater, 530 MPa or greater, 535 MPa or greater, 540 MPa or greater, 545 MPa or greater, 550 MPa or greater, 555 MPa or greater, 560 MPa or greater, 565 MPa or greater, 570 MPa or greater, or 575 MPa or greater, after processing according to the methods described herein.

[0091] The increase in ultimate tensile strength can be at least 5 MPa (e.g., from 15 MPa to 50 MPa). For example, the increase in yield strength can be 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 11 MPa, 12 MPa, 13 MPa, 14 MPa, 15 MPa, 16 MPa, 17 MPa, 18 MPa, 19 MPa, 20 MPa, 21 MPa, 22 MPa, 23 MPa, 24 MPa, 25 MPa, 26 MPa, 27 MPa, 28 MPa, 29 MPa, 30 MPa, 31 MPa, 32 MPa, 33 MPa, 34 MPa, 35 MPa, 36 MPa, 37 MPa, 38 MPa, 39 MPa, 40 MPa, 41 MPa, 42 MPa, 43 MPa, 44 MPa, 45 MPa, 46 MPa, 47 MPa, 48 MPa, 49 MPa, 50 MPa, or greater than 50 MPa.

[0092] In some examples, the aluminum alloy products have an ultimate tensile strength of greater than 350 MPa after processing according to the methods described herein. For example, the aluminum alloy products can have a yield strength of 360 MPa or greater, 365 MPa or greater, 370 MPa or greater, 375 MPa or greater, 380 MPa or greater, 385 MPa or greater, 390 MPa or greater, 395 MPa or greater, 400 MPa or greater, 405 MPa or greater, 410 MPa or greater, 415 MPa or greater, 420 MPa or greater, 425 MPa or greater, 430 MPa or greater, 435 MPa or greater, 440 MPa or greater, 445 MPa or greater, 450 MPa or greater, 455 MPa or greater, 460 MPa or greater, 465 MPa or greater, 470 MPa or greater, or 475 MPa or greater, 480 MPa or greater, 485 MPa or greater, 490 MPa or greater, 495 MPa or greater, 500 MPa or greater, 505 MPa or greater, 510 MPa or greater, 515 MPa or greater, 520 MPa or greater, 525 MPa or greater, 530 MPa or greater, 535 MPa or greater, 540 MPa or greater, 545 MPa or greater, 550 MPa or greater, 555 MPa or greater, 560 MPa or greater, 565 MPa or greater, 570 MPa or greater, or 575 MPa or greater, after processing according to the methods described herein.Methods of Using

[0093] The alloy products and methods described herein can be used in automotive and / or transportation applications, including motor vehicle, aircraft, and railway applications, or any other desired application. In some examples, the products and methods can be used to prepare motor vehicle body part products, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.

[0094] The products and methods described herein can also be used in electronics applications, to prepare, for example, external and internal encasements. For example, the products and methods described herein can also be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones) and tablet bottom chassis.

[0095] In certain aspects, the products and methods can be used to prepare aerospace vehicle body part products. For example, the disclosed products and methods can be used to prepare airplane body parts, such as skin alloys.

[0096] The products and methods can be used in any other desired application.EXAMPLESExample 1: Mechanical Properties of Highly Formable High Strength Aluminum Alloys

[0097] A cast aluminum alloy product was prepared, using the methods described herein, and described further below, from an aluminum alloy compositions including 0.11 wt. % Si, 0.21 wt. %, 0.20 wt. %, 0.10 wt. %, 3.29 wt. %, 0.0 wt. % Cr, 4.34 wt. % Zn, 0.02 wt. % Ti, 0.1 wt. % Zr, up to 0.15 wt. % impurities, and the remainder aluminum (referred to herein as “Example 1”). Samples from Example 1 were subject to mechanical testing. In some cases, additional paint baking steps were employed, in which the aluminum alloy product was heated to a temperature of 180° C. and maintained at this temperature for 30 minutes. In some cases, additional tempers were used on the aluminum alloy to compare the mechanical properties under different methods of producing an aluminum alloy product. In some cases, steps were left out of the method of producing while some steps were made optional to further test the method of producing the alloy and corresponding mechanical properties.

[0098] FIGS. 1A-1C provides graphs of the yield strength, ultimate tensile strength and total elongation of an aluminum alloy composition described herein at 2.0 mm gauge with water quenching (WQ) (1A), 2.4 mm gauge with air quenching (AQ) (1B), and 2.4 mm gauge with WQ (1C) during natural aging response, according to some embodiments described herein. Example 1 aluminum alloys were produced via methods described herein and further underwent a T4 temper with pre-aging (denoted as PX, in some cases) to study the effect of natural aging on the alloy. FIG. 1A indicate that Example 1 aluminum alloy prepared as described and further rolled to 2.0 mm and water quenched (WQ) initially had a 292 MPa yield stress that increased to 312 MPa after 5.5 months of natural aging. The ultimate tensile strength initially started at 438 MPA and increased to 458 MPA after 5.5 months. Additionally, the total elongation increased from 18.9 to 22.4% over the 5.5-month period. FIG. 1B indicates that Example 1 aluminum alloy and prepared via methods described herein further rolled to 2.4 mm (AQ) initially had a yield stress of 301 MPa that increased to 317 MPa after 5.5 months. The ultimate tensile strength increased from 434 MPa to 454 MPa over the same 5.5 month period, while the total elongation increased from 18.2 to 19.6%. FIG. 1C demonstrated that Example 1 aluminum alloy and prepared via methods described herein further rolled to 2.4 mm WQ initially had a yield stress of 308 MPa that increased to 323 MPa after 5.5 months. The ultimate tensile strength increased from 440 MPa to 455 MPa over the same 5.5 month period, while the total elongation increased from 18.2 to 20.9%. The results indicate that the aluminum alloy described herein and produced via methods described above have improved mechanical properties with natural aging.

[0099] FIGS. 2A-2B provides graphs of the yield strength (YS), ultimate tensile strength (UTS) and total elongation (TE) of an aluminum alloy composition described herein after multiple paint back cycles and T4 temper (2A) or T6 Temper (2B) conditions, according to some embodiments described herein. Example 1 aluminum alloy initially had average yield strength (YS) of 295 MPa, an ultimate tensile strength of 444 MPa and a total elongation of 20.1% after 2 months of natural aging (FIG. 2A). After 1 paint bake cycle, the yield strength increased to 369 MPa, the ultimate tensile strength (UTS) decreased to 434 MPa, and the total elongation (TE) decreased to 12.8%. With the inclusion of an additional paint bake cycle, the yield strength further increased to 388 MPa, the ultimate tensile strength increased to 449 MPa and the total elongation further decreased to 11.8%. Another paint bake cycle resulted in a yield strength of 389 MPa, an ultimate tensile strength of 449 MPa, and a total elongation of 12.9%. Example 1 aluminum alloy underwent a T6 temper under the same processing as described above. The alloy had improved mechanical properties including 441 MPa yield strength, 495 MPa UTS, and a TE of 14.0%. (FIG. 2B). After a single paint bake, the aluminum alloy had a YS of 406 MPa, a UTS of 464 MPa, and a TE of 15.2%. The additional of another paint bake resulted in a decrease in the three properties to 398 MPa YS, 458 MPa UTS, and 12.5% TE. Under a third paint bake cycle, the resulting aluminum alloy had a 452 MPa UTS, 392 MPa YS, and 13.0% TE. These results indicate that the mechanical properties of the aluminum alloy under T4 temper may be improved with additional paint bake cycles while the mechanical properties may decrease in a T6 alloy with additional paint bake cycles.

[0100] FIG. 3 provides a graph of wrap bend for example aluminum alloy described herein after T4 and T6 tempers compared to comparative example 1, according to some embodiments described herein. Example 1 aluminum alloy under a T4 temper experienced an 0.81 wrap bend in the longitudinal direction, 1.02 r / t in the transverse, and 0.81 r / t in the d direction. The same aluminum alloy under a T6 temper had an 0.89 r / t in the longitudinal, a 1.15 r / t in the transverse, and 0.89 in the d direction. Comparative example 1 under a T4 temper was at or below 0.4 r / t in each of the three directions with comparative example 1 under a T82 was at or below 0.7 r / t in each of the three directions. The aluminum alloy of Example 1 has a higher wrap bend ratings when compared to currently available alloys under similar temper conditions.

[0101] FIGS. 4A-4B provides photographs (4A) and die depths (4B) of various rivets and die designs in an aluminum alloy described herein, according to some embodiments described herein. Example 1 aluminum ally was rolled into a 2.0 mm plate under T4 temper conditions. Two rivet lengths and three different die designs at various depths were tested. As can be seen from the photographs of the die (FIG. 4A) the 5×6H4 / DG10-180 experienced cracking and decreased performance when compared to 5×6H4 / DC10-150 die. Additionally, the 5×5H4 / DP10-200 experienced cracking when performed. The flat die had no cracking at a depth of 150 mm with severe cracking starting at 160 mm (FIG. 4B). The 5×5H4 pip die reached a maximum depth of 175 mm before severe cracking appeared.

[0102] FIG. 5 provides photographs of 2.0 mm WQ, 2.4 mm AC, and 2.4 mm WQ aluminum alloys under 30 kA and 34 Ka, according to some embodiments described herein. Spot welds were formed in the Example 1 aluminum alloy on 2.0 mm WQ, 2.4 mm WQ, and 2.4 mm AC samples. The results show no visible cracks or pinholes found in any of the spot welds from either current flow. The 2.0 mm WQ had an expulsion from 30 kA to 33 kA, while 2.4 mm AC also had an expulsion from 32 kA to 34 kA. The 2.4 mm WQ showed no expulsion and a good weld size during testing.

[0103] To further test the Example 1 aluminum alloy, formability testing was performed in the form of cup draw testing for both flat (FIGS. 6A and 6B) and round (FIGS. 7A and 7B). The results of the flat (FIGS. 6A and 6B) formability testing show that the natural aging after 150 hours did not impact the forming depth of example 1 aluminum alloy under natural aging, pre-aging not T6 temper. Comparative example 1 under similar conditions decreased in forming depth from 55 mm to below 30 mm after 24 hours of natural aging. Additionally, under pre-aging, the forming depth was decreased for each of the comparative example 1 tests, while example 1 did not experience any cracking for the conditions tested. Similar results were experienced for the round bottom test (FIGS. 7A and 7B) with the exception of the pre-aging and T6 temper. Under those conditions the forming depth was greatly reduced to under 33 mm. Example 1 aluminum alloy is capable of fully drawing cup samples under natural aging, pre-aging and T6 temper while comparable alloy compositions result in a sharp decrease in formability after 1 day of natural aging.

[0104] FIG. 8 provides a graph of the minor strain vs major strain for comparative examples 1-3 and example 1 aluminum alloys described herein, according to some embodiments described herein. The example 1 alloy had a forming limit curve that was lower when compared to comparative examples 1-3 aluminum alloys. The forming limit curve was lower but the strength of example 1 alloy was nearly double when compared to comparative examples 1-3 shown in Table 5.TABLE 5TemperAlloyYS (MPa)UTS (MPa)TE (%)T4Comp. Ex. 212622926.3Comp. Ex. 116930126.0Ex. 131645219.7WComp. Ex. 315636222.5

[0105] To test the practical application of the alloy composition when compared to Comparative examples 1-3, forming trials were conducted (FIGS. 9A-9B). The comparative examples were drawn to 90 mm without cracking appearing in the alloy while example 1 cracks at 75 mm draw depth. Example 1 additionally experienced a stress of greater than 600 MPa at a strain of 0.40 while comparative alloys stress was under 500 MPa for the same strain. To further evaluate the forming of the aluminum alloys, springback testing was performed (FIG. 10). The higher strength materials (i.e., example 1 alloy) showed higher springback while thinner gauge materials showed a similar trend. While not shown here, different forming speeds did not result in any noticeable effects.

[0106] 7xxx series aluminum alloys have been known to be susceptible to intergranular corrosion. Without being bound to any particular theory, it is believed that the lack of Zr, and low amounts of Cu and Mg likely contributes to the susceptibility of the alloy to IGC. Thus, the aluminum alloy described herein incorporates Zr, and increased Cu and Mg thereby improving the IGC of the alloy as demonstrated in FIGS. 11A-11C. For example, the alloy at 2.0 mm and WQ under a T4 temper and paint back treatment had an IGC depth of 23 mm after 24 hours that decreased to 16 mm after 48 hours. After T6 temper the IGC depth was 24 mm after 24 hours and decreased to 19 mm after 48 hours. The IGC of the alloy after T6 temper and a paint bake treatment had an increased IGC when compared to the T4 temper alloy. Additionally, the 2.4 mm WQ and AQ alloy samples had increased IGC depths when compared to the 2.0 mm WQ sample. For example, the 2.4 mm WQ sample under T6 temper had an IGC of 22 mm in 24 hours and increased to 56 mm after 48 hours. Interestingly, the 2.4 mm AQ sample under a T6 temper decreased in IGC depth between the 24 hour and 48-hour time cycles. The microscopy images (FIGS. 11B and 11C) both showed pitting in the samples from T4 with additional paint bake treatments. The results indicate that there was no IGC attack observed after 48 hours with a maximum below 60 mm.

[0107] FIG. 12 provides microscopy images of the exfoliation testing of an example aluminum alloy, according to some embodiments described herein. The 2.4 mm WQ alloy after a T4 temper and an additional paint bake treatments was imaged at three independent locations to test the exfoliation of the alloy. The results as indicated in Table 6 further indicate that the alloy showed moderate and superficial ratings during exfoliation treatment in both 24 hour and 48-hour time frames. Additionally, the results indicate that the T4 temper with a paint bake treatment showed an overall better performance when compared to T6 and T6 with a paint bake. The results are summarized in Table 6, below.TABLE 6Internal Spec.Per ASTM-G34 SpecMass Loss (mg / cm2)Sample IDTemper24 hour48 hour24 hour48 hour2.0 mm WQT4 + PBEAEA7.3910.92Ex. 1T6EAEA10.9613.20T6 + PBEAEA8.8611.342.4 mm WQT4 + PBEAEA7.0913.79Ex. 1T6EAEA10.8313.40T6 + PBEAEA / EB9.3716.462.4 mm AQT4 + PBEAEA8.9311.04Ex. 1T6EAEA11.5013.91T6 + PBEAEA9.5412.83

[0108] Additional testing for Stress Corrosion Cracking (SCC) was performed to evaluate the aluminum alloy compositions described herein and additional steps in the method of making the aluminum alloy. The SCC testing performed was SCC-ASTM-G47 as an alternative to the immersion 40-day test FIGS. 13A-13C. The results indicate that the Example 1 alloy under pre-exposure, unstressed, and stressed conditions had relatively similar Max tensile stress. For example, the T4+PB had around 440 MPa for the three conditions with a slight improvement seen in the T6+PB sample. Additionally, the 2.4 mm AQ sample alloy under T4+PB had around a 435 MPa and the T6+PB had around 450 MPa for the three test conditions. The max axial strain indicated similar results with the three testing conditions showing relatively similar results with the T4+PB for both the 2.4 mm WQ and 2.4 mm AQ having slightly higher max axial strain than the T6+PB testing group. The results indicate however, that there were no SCC failures for any of the stressed samples, while residual strength of greater that 80% was seen for each of the cases.

[0109] Additional steps were taken to evaluate the microstructure of the aluminum alloy from T4 2 mm WQ, 2.4 mm WQ, and 2.4 mm AQ samples using STEM (FIG. 14). The results indicate that there were no differences observed in the formation of precipitates between the 2.0 mm and the 2.4 mm gauges. No evidence of grain boundary precipitates with lower quench rate, less quench sensitive due to low solute content. Example 1 alloy may be less sensitive to quenching due to the low solute content within the microstructure and did not show much alteration on tensile bending behavior for WQ vs, FAC. The Example 1 alloy was stabilized with pre-aging treatment which showed potential for cold forming with improved yield strength after direct paint bake simulation and retained the improve mechanical properties after multiple paint bake treatments and T6 temper.EMBODIMENTS

[0110] Embodiment 1: A method for producing an aluminum alloy product, comprising: casting a molten aluminum alloy to form an ingot or a slab; hot rolling the ingot or the slab to produce a sheet; subjecting the sheet to a solutionizing heat treatment to form a solutionized sheet; pre-aging the solutionized sheet to form a pre-aged sheet; and subjecting the pre-aged sheet to at least one paint bake heat treatment to form the aluminum alloy product; wherein the aluminum alloy comprises Mg and Cu; and wherein the aluminum alloy product has a service strength of at least 370 MPa.

[0111] Embodiment 2: The method according to Embodiment 1, wherein the aluminum alloy comprises: up to 0.25 wt. % Si, up to 0.4 wt. % Fe, up to 0.4 wt. % Cu, up to 0.3 wt. % Mn, up to 3.6 wt. % Mg, up to 0.1 wt. % Cr, up to 4.5 wt. % Zn, up to 0.1 wt. % Ti, up to 0.2 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

[0112] Embodiment 3: The method according to Embodiment 1, wherein the aluminum alloy comprises: from 0 to 0.25 wt. % Si, from 0 to 0.4 wt. % Fe, from 0 to 0.4 wt. % Cu, from 0.1 to 0.3 wt. % Mn, from 2.3 to 3.6 wt. % Mg, from 0 to 0.1 wt. % Cr, from 3.5 to 4.5 wt. % Zn, up to 0.1 wt. % Ti, up to 0.2 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

[0113] Embodiment 4: The method according to Embodiment 1, wherein the aluminum alloy comprises: from 0 to 0.25 wt. % Si, from 0 to 0.4 wt. % Fe, from 0.11 to 0.4 wt. % Cu, from 0.1 to 0.3 wt. % Mn, from 2.3 to 3.6 wt. % Mg, from 0 to 0.1 wt. % Cr, from 3.5 to 4.5 wt. % Zn, up to 0.1 wt. % Ti, up to 0.2 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

[0114] Embodiment 5: The method according to Embodiment 1, wherein the aluminum alloy comprises: from 0 to 0.25 wt. % Si, from 0 to 0.4 wt. % Fe, from 0 to 0.4 wt. % Cu,

[0115] from 0.1 to 0.3 wt. % Mn, from 2.3 to 3.6 wt. % Mg, from 0 to 0.1 wt. % Cr,

[0116] from 3.5 to 4.5 wt. % Zn, up to 0.1 wt. % Ti, from 0.05 to 0.2 wt. % Zr, up to 0.15 wt. % impurities, and Al, wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

[0117] Embodiment 6: The method according to any of the preceding Embodiments, wherein the method further comprises homogenizing the ingot or the slab before the hot rolling.

[0118] Embodiment 7: The method according to any of the preceding Embodiments, wherein the at least one paint bake heat treatment is conducted at a temperature from 75 to 250° C. for a period of from 15 minutes to 3 hours.

[0119] Embodiment 8: The method according to any of the preceding Embodiments, wherein the at least one paint bake heat treatment is conducted at a temperature from 100 to 200° C. for a period of from 15 minutes to 2 hours.

[0120] Embodiment 9: The method according to any of the preceding Embodiments, wherein the at least one paint bake heat treatment is conducted at a temperature from 150 to 180° C. for a period of from 15 minutes to 45 minutes.

[0121] Embodiment 10: The method according to any of the preceding Embodiments, wherein the aluminum alloy product is formable at room temperature.

[0122] Embodiment 11: The method according to any of the preceding Embodiments, wherein the aluminum alloy product is formable at temperatures below room temperature.

[0123] Embodiment 12: The method according to any of the preceding Embodiments, wherein the aluminum alloy product has a service strength of at least 390 MPa in T4 temper after at least two paint bake cycles.

[0124] Embodiment 13: The method according to any of the preceding Embodiments, wherein the aluminum alloy product has a service strength of at least 400 MPa in T6 temper after at least two paint bake cycles.

[0125] Embodiment 14: The method according to any of the preceding Embodiments, wherein the pre-aging is conducted at a temperature from 50 to 200° C. for a period of time of from 1 to 24 hours.

[0126] Embodiment 15: The method according to any of the preceding Embodiments, wherein the sheet is cold rolled prior to the solutionizing heat treatment.

[0127] Embodiment 16: The method according to Embodiment 6, wherein the homogenizing comprises heating the ingot or slab to a temperature of at least 450° C. and maintaining the ingot or slab at the temperature of at least 450° C. for a time period of at least 90 minutes.

[0128] Embodiment 17: The method according to any of the preceding Embodiments, wherein the ingot or slab is hot rolled to a thickness of less than 7 mm and is then cold rolled to a thickness of less than 4 mm.

[0129] Embodiment 18: The method according to any of the preceding Embodiments, further comprising artificially aging the pre-aged sheet prior to the at least one paint bake treatment.

[0130] Embodiment 19: The method according to Embodiment 18, wherein the pre-aged sheet is artificially aged at a temperature from 100 to 250° C. for a time period of from 1 to 72 hours.

[0131] Embodiment 20: An aluminum alloy product prepared according to the method of any of the preceding Embodiments.

[0132] Embodiment 21: The aluminum alloy product according to Embodiment 20, wherein the aluminum alloy product has an ultimate tensile strength of at least 420 MPa following a 40 day immersion test according to SCC-ASTM G47.

[0133] All patents, publications and abstracts cited above are incorporated herein by reference in their entireties. Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptions thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

1. A method for producing an aluminum alloy product, comprising:casting a molten aluminum alloy to form an ingot or a slab;hot rolling the ingot or the slab to produce a sheet;subjecting the sheet to a solutionizing heat treatment to form a solutionized sheet;pre-aging the solutionized sheet to form a pre-aged sheet; andsubjecting the pre-aged sheet to at least one paint bake heat treatment to form the aluminum alloy product;wherein the aluminum alloy comprises Mg and Cu; andwherein the aluminum alloy product has a service strength of at least 370 MPa.

2. The method according to claim 1, wherein the aluminum alloy comprises:up to 0.25 wt. % Si,up to 0.4 wt. % Fe,up to 0.4 wt. % Cu,up to 0.3 wt. % Mn,up to 3.6 wt. % Mg,up to 0.1 wt. % Cr,up to 4.5 wt. % Zn,up to 0.1 wt. % Ti,up to 0.2 wt. % Zr,up to 0.15 wt. % impurities, andAl,wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

3. The method according to claim 1, wherein the aluminum alloy comprises:from 0 to 0.25 wt. % Si,from 0 to 0.4 wt. % Fe,from 0 to 0.4 wt. % Cu,from 0.1 to 0.3 wt. % Mn,from 2.3 to 3.6 wt. % Mg,from 0 to 0.1 wt. % Cr,from 3.5 to 4.5 wt. % Zn,up to 0.1 wt. % Ti,up to 0.2 wt. % Zr,up to 0.15 wt. % impurities, andAl,wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

4. The method according to claim 1, wherein the aluminum alloy comprises:from 0 to 0.25 wt. % Si,from 0 to 0.4 wt. % Fe,from 0.11 to 0.4 wt. % Cu,from 0.1 to 0.3 wt. % Mn,from 2.3 to 3.6 wt. % Mg,from 0 to 0.1 wt. % Cr,from 3.5 to 4.5 wt. % Zn,up to 0.1 wt. % Ti,up to 0.2 wt. % Zr,up to 0.15 wt. % impurities, andAl,wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

5. The method according to claim 1, wherein the aluminum alloy comprises:from 0 to 0.25 wt. % Si,from 0 to 0.4 wt. % Fe,from 0 to 0.4 wt. % Cu,from 0.1 to 0.3 wt. % Mn,from 2.3 to 3.6 wt. % Mg,from 0 to 0.1 wt. % Cr,from 3.5 to 4.5 wt. % Zn,up to 0.1 wt. % Ti,from 0.05 to 0.2 wt. % Zr,up to 0.15 wt. % impurities, andAl,wherein Cu and Mg are present in a total amount of less than 3.6 wt. %.

6. The method according to claim 1, wherein the method further comprises homogenizing the ingot or the slab before the hot rolling.

7. The method according to claim 1, wherein the at least one paint bake heat treatment is conducted at a temperature from 75 to 250° C. for a period of from 15 minutes to 3 hours.

8. The method according to claim 1, wherein the at least one paint bake heat treatment is conducted at a temperature from 100 to 200° C. for a period of from 15 minutes to 2 hours.

9. The method according to claim 1, wherein the at least one paint bake heat treatment is conducted at a temperature from 150 to 180° C. for a period of from 15 minutes to 45 minutes.

10. The method according to claim 1, wherein the aluminum alloy product is formable at room temperature, at temperatures below room temperature, or at room temperature and at temperatures below room temperature.

11. (canceled)12. The method according to claim 1, wherein the aluminum alloy product has a service strength of at least 390 MPa after at least two paint bake cycles in T4 temper.

13. The method according to claim 1, wherein the aluminum alloy product has a service strength of at least 400 MPa after at least two paint bake cycles in T6 temper.

14. The method according to claim 1, wherein the pre-aging is conducted at a temperature from 50 to 225° C. for a period of time from 0.5 to 24 hours.

15. The method according to claim 1, wherein the sheet is cold rolled prior to the solutionizing heat treatment.

16. The method according to claim 6, wherein the homogenizing comprises heating the ingot or slab to a temperature of at least 450° C. and maintaining the ingot or slab at the temperature of at least 450° C. for a time period of at least 90 minutes.

17. The method according to claim 1, wherein the ingot or slab is hot rolled to a thickness of less than 10 mm and is then cold rolled to a thickness of less than 4 mm.

18. The method according to claim 1, further comprising artificially aging the pre-aged sheet prior to the at least one paint bake treatment.

19. The method according to claim 18, wherein the pre-aged sheet is artificially aged at a temperature from 100 to 250° C. for a time period of from 0.5 to 72 hours.

20. An aluminum alloy product prepared according to the method of claim 1.

21. The aluminum alloy product according to claim 20, wherein the aluminum alloy product has an ultimate tensile strength of at least 420 MPa following a 40 day immersion test according to SCC-ASTM G47.

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