4xxx series aluminum alloys for brazing applications comprising recycled content

Abstract

4xxx series aluminum alloys may be fabricated with a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). Said aluminum alloys may have higher copper and manganese concentrations than traditional 4xxx series aluminum alloys. For example, a 4xxx series aluminum alloy may include: 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum. Said aluminum alloy may be produced from at least 50 wt. % recycled content, where at least 50 wt. % of the recycled content is a mixed cladded alloy recycled.

Description

4XXX SERIES ALUMINUM ALLOYS FOR BRAZING APPLICATIONS COMPRISING RECYCLED CONTENTCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 604,354, filed on November 30, 2023, the content of which is hereby incorporated by reference in its entirety.FIELD

[0002] The disclosure is directed to 4xxx series aluminum alloys fabricated with a high recycled content. The disclosure further relates to fabrication methods and applications of said 4xxx series aluminum alloys.BACKGROUND

[0003] Aluminum alloys suitable for brazing applications include brazing cladding alloys typically produced from commercial aluminum smelter purity grades, to which Si is added. Such conventional brazing aluminum alloys contain between 6 wt. % and 13 wt. % Si, <0.8 wt. % Fe and other elements like Mg, Zn, Ti or Bi depending on the selected brazing method and application. Commercial aluminum smelter purity grades are typically higher in carbon footprint, than secondary or recycled aluminum, dependent to the energy source used in the smelting process. It is desirable to decrease the carbon footprint of the clad sheet aluminum alloys suitable for brazing applications by increasing the content of recycled aluminum alloys in such alloys, to achieve industrial targets related to material environment impacts.SUMMARY

[0004] Covered embodiments of the invention 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.

[0005] In an aspect, described herein are 4xxx series aluminum alloys fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). In some examples, a 4xxx series aluminum alloy comprises: 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum; and wherein the 4xxx series aluminum alloy comprises at least 50 wt. % recycled content, and wherein at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). In some examples, the recycled content comprises a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, or a combination thereof. In some examples, the 4xxx series aluminum alloy comprises at least 70 wt. % recycled content, and wherein at least 55 wt. % of the recycled material is the mixed cladded alloy recycled material. In some examples, the 4xxx series aluminum alloy comprises: 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.2 wt. % to 1 wt. % copper, 0.3 wt. % to 1.5 wt. % manganese, 0.01 wt. % to 2 wt. % magnesium, 0.01 wt. % to 0.1 wt. % chromium, 0.01 wt. % to 3 wt. % zinc, 0.01 wt. % to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum. In some examples, the 4xxx series aluminum alloy comprises: 6 wt. % to 11 wt. % silicon, 0.2 wt. % to 0.5 wt. % iron, 0.2 wt. % to 1 wt. % copper, 0.4 wt. % to 1.25 wt. % manganese, 0.01 wt. % to 2 wt. % magnesium, 0.01 wt. % to 0.07 wt. % chromium, 0.01 wt. % to 1 wt. % zinc, 0.01 wt. % to 0.15 wt. % titanium, up to 0.05 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum.

[0006] In another aspect, described herein are products that include the 4xxx series aluminum alloys, including the foregoing 4xxx series aluminum alloys produced from a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). In some examples, a cladded aluminum sheet comprises: a core layer comprising an aluminum alloy; and a brazing cladding layer on one side of the core layer or on both sides of the core layer, wherein the brazing cladding layer is fabricated from the 4xxx series aluminum alloy produced from a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, preconsumer recycled material). In some examples, the core layer is fabricated from a 3xxx series aluminum alloy or a 6xxx series aluminum alloy. In some examples, the cladded aluminum sheet comprises an interlayer between the core layer and the brazing cladding layer. In someexamples, the cladded aluminum sheet comprises a corrosion protection liner and / or a corrosion protection interlayer.

[0007] In other aspects, described herein are methods of preparing products including the 4xxx series aluminum alloys produced from a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). In some examples, a process for preparing the cladded aluminum sheet comprises: fusion casting (also referred to as co-casting or simultaneously casting) the core layer and a brazing cladding layer comprising the 4xxx series aluminum alloys produced from a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). In some examples, a process comprises joining by brazing at least one first aluminum alloy form fabricated from the 4xxx series aluminum alloys produced from a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, preconsumer recycled material) with a second aluminum alloy form. Products produced from said methods can include, but are not limited to, chillers, heaters, evaporator plates, evaporators, radiators, heater cores, condensers, charge air coolers / intercoolers, oil coolers, cold plates, base plate, tubes and tubestock, pipes, finstock, stamped parts and bracketry, and / or manifolds and assemblies thereof.

[0008] Another example is a process of joining two or more aluminum forms by brazing, where at least one of the two or more aluminum forms consists of a brazing cladding layer fabricated from the 4xxx series aluminum alloys produced from a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). In some examples, the process comprises: assembling and securing the two or more aluminum forms together; heating the two or more aluminum forms to a brazing temperature until joints are created among the two or more aluminum forms by capillary forces; and cooling the two or more aluminum forms below solidus of the brazing cladding layer. In some examples, the brazing temperature is from 570 °C to 620 °C. In some instances, the brazing is a controlled atmosphere brazing where the 4xxx series aluminum alloy comprises up to 0.3 wt. % magnesium. In some instances, brazing is a vacuum brazing where the 4xxx series aluminum alloy comprises from 0.2 wt. % to 1.5 wt. % magnesium. In some instances, brazing is by flame brazing where the recycled 4xxx series aluminum alloy is used as or in conjunction with braze rings and shims to facility joining. In some instances, brazing is by induction brazing where the recycled 4xxx series aluminum alloy is used as a localized clad or separate filler alloy element. In some examples, a process, for preparing an aluminum material comprising a core layer and a brazing cladding layer, comprises: casting a 4xxx series aluminum alloy using at least 50 wt. % recycled content, basedon a total weight of materials used for casting, wherein at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material), and wherein the 4xxx series aluminum alloy comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum; rolling the 4xxx series aluminum alloy to a required thickness, thus producing the brazing cladding layer; assembling the brazing cladding layer onto at least one side of the core layer; and hot roll bonding the brazing cladding layer onto the core layer. In some instances, the casting also uses smelter grade aluminum and / or silicon. In some instances, the recycled material comprises at least 50 wt. % of a non-4xxx series aluminum alloy. In some instances, the recycled content comprises a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, or a combination thereof.

[0009] In some instances, joining can be achieved by laser welding where the recycled 4xxx series aluminum alloy is used as a clad or separate filler alloy.

[0010] Further aspects, obj ects, and advantages of the invention will become apparent upon consideration of the detailed description that follow.BRIEF DESCRIPTION OF THE FIGURES

[0011] FIG. 1 is a photograph of an aluminum alloy angle joined to a cladded aluminum sheet.

[0012] FIG. 2 is a light microscope image of the braze joint of an aluminum alloy angle joined to a cladded aluminum sheet.

[0013] FIG. 3 is a light microscope image of the braze joint of an aluminum alloy angle joined to a cladded aluminum sheet.DETAILED DESCRIPTION OF THE INVENTION

[0014] Described herein are 4xxx series aluminum alloys fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). Herein, the term “mixed cladded alloy recycled material” refers to the waste materials from cladded aluminum alloy products (e.g., coils, plates, sheets, tubing, pipes, manifolds, condensers, and the like) and / or the production thereof. Herein, the term “mixed cladded alloy, pre-consumerrecycled material” refers to the process waste materials generated during the production of cladded aluminum alloy products. As described in more detail herein, cladded aluminum alloy products include multilayer structures with a core layer and a cladding layer on at least one side of the core layer. The alloy in each of the core layer and the cladding layer are typically different series of aluminum alloys. Therefore, the mixed cladded alloy recycled material may include two or more series of aluminum alloys.

[0015] While cladded aluminum alloy products can be made of many different series of aluminum alloy, 4xxx series aluminum alloys are typically used in the cladding layer, and 3xxx and 6xxx series aluminum alloys are typically used in the core layer. Therefore, aluminum alloys cast from mixed cladded alloy recycled materials (e.g., mixed cladded alloy, preconsumer recycled materials) are outside the traditional 4xxx series aluminum alloy specifications and dominated by the 3xxx series and / or 6xxx series compositions. Commonly, some of these materials still having an acceptable level of Si are recycled to produce new 3xxx core slabs. However, such mixed cladded alloy recycled materials have seen little to no use so far in recycling to produce aluminum alloy for cladding layer suitable for brazing (also referred to herein as a brazing cladding layer).

[0016] The present disclosure includes 4xxx series aluminum alloys suitable for producing brazing cladding layers and fabricated using high amounts of a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). Said 4xxx series aluminum alloys may have higher copper and manganese concentrations than traditional 4xxx series aluminum alloys, as further described herein. Advantageously, even with the composition change, the 4xxx series aluminum alloys of the present disclosure may have a solidus temperature and a liquidus temperature similar to that of the traditional 4xxx series aluminum alloys, which allows for minimal, if any, changes to fabrication and brazing processes.

[0017] Additionally, the chemistry of the 4xxx series aluminum alloys of the present disclosure may afford the cladding layers produced therefrom an improved corrosion resistance because the open circuit potential (OCP) corrosion values of the brazing clad layer and the core layer may be closer.

[0018] Further, the use of recycled content in producing the cladding layer reduces the energy consumption because less, if any, prime aluminum is needed. Accordingly, not only do the 4xxx series aluminum alloys of the present disclosure have a lower carbon footprint as a consequence of the high recycled content, but an additional positive effect is a much lowerenergy consumption compared to standard amount of energy used when low carbon prime aluminum is produced.Definitions and Descriptions

[0019] 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.

[0020] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “4xxx .” 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.

[0021] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0022] As used herein, a plate generally has a thickness of greater than about 15 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, or greater than 100 mm.

[0023] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 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.

[0024] As used herein, a sheet generally refers to an aluminum alloy product having a thickness of less than about 4 mm. For example, a 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] Reference is 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.”

[0026] The following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %) based on the total weight of the alloy. In certainexamples of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of the impurities.

[0027] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

[0028] 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.

[0029] The terms “cladding,” “clad,” “cladding layer,” and the related terms are used generally to refer to a relatively thin surface layer of a multilayer aluminum alloy. The terms “core,” “core layer” and the related terms are used to refer to a relatively thicker layer of a multilayer aluminum alloy. A clad sheet aluminum alloy can have one or more cladding layers on both sides of the sheet, in which case a core layer is indeed an internal layer of the multilayer material. However, a clad sheet alloy can also have one or more cladding layers on only one side of the sheet, in which case the core layer can also be on a surface. The core layer and cladding layer or layers typically have different chemical compositions. A clad sheet alloy can have two or more different cladding layers all with different compositions and properties.

[0030] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example 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 temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can 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%, about69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric 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 anywhere in between.

[0031] All ranges disclosed herein are to be understood to encompass 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. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt. %).4xxx Series Aluminum Alloy Compositions Fabricated using Mixed Cladded Alloy Recycled Material

[0032] Described below are 4xxx series aluminum alloys that can be fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). The 4xxx series aluminum alloys can have the following elemental composition as provided in Table 1 :Table 1

[0033] In other examples, the 4xxx series aluminum alloys can have the following elemental composition as provided in Table 2.Table 2

[0034] In other examples, the 4xxx series aluminum alloys can have the following elemental composition as provided in Table 3.Table 3

[0035] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 1-3, the predominant element is aluminum (Al), sometimes called “remainder Al.” In other words, the term “remainder” can be used to describe predominant aluminum (Al) content in the aluminum alloys described herein.

[0036] In certain examples, the disclosed alloy includes silicon (Si) in an amount from about 6 % to about 13 % (e.g., from 6 % to 10 %, from 7 % to 11 %, from 8 % to 12 %, or from 9 % to 13 %) based on the total weight of the alloy. For example, the alloy can include 6.0 %, 6.2 %, 6.4 %, 6.6 %, 6.8 %, 7.0 %, 7.2 %, 7.4 %, 7.6 %, 7.8 %, 8.0 %, 8.2 %, 8.4 %, 8.6 %, 8.8 %, 9.0 %, 9.2 %, 9.4 %, 9.6 %, 9.8 %, 10.0 %, 10.2 %, 10.4 %, 10.6 %, 10.8 %, 11.0 %, 11.2 %, 11.4 %, 11.6 %, 11.8 %, 12.0 %, 12.2 %, 12.4 %, 12.6 %, 12.8 %, or 13.0 % Si. All expressed in wt. % based on the total weight of the aluminum alloy.

[0037] In certain examples, the disclosed alloy includes iron (Fe) in an amount from about 0.1 % to about 0.7 % (e.g., from 0.1 % to 0.6 %, from 0.2 % to 0.6 %, from 0.1 % to 0.5 %, from 0.2 % to 0.5 %, or from 0.2 % to 0.4 %) 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 %, 0.31 %, 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 %, or 0.70 % Fe. All expressed in wt. % based on the total weight of the aluminum alloy.

[0038] In certain examples, the disclosed alloy includes copper (Cu) in an amount from about 0.1 % to about 1.5 % (e.g., from 0.2 % to 1.5 %, from 0.2 % to 1.25 %, from 0.2 % to 1 %, or from 0.2 % to 0.75 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05%, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, or 1.50 % Cu. All expressed in wt. % based on the total weight of the aluminum alloy.

[0039] In certain examples, the alloy can include manganese (Mn) in an amount from about 0.1 % to about 1.9 % (e.g., from 0.3 % to 1.5 %, from 0.4 % to 1.25 %, from 0.75 % to 1.25 %, or from 1.0 % to 1.25 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, or 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, or 1.90 % Mn. All expressed in wt. % based on the total weight of the aluminum alloy.

[0040] In certain examples, the disclosed alloy includes magnesium (Mg) in an amount of up to about 2 % (e.g., from 0 % to 2 %, from 0.01 % to 2 %, from 0.01 % to 0.2 %, from 0.01 % to 0.1 %, from 0.2 % to 1.5 %, from 0.2 % to 1.5 %, or from 0.5 % to 2 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.05 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95 %, or 2.00 % Mg. In some cases, the disclosed alloy does not include Mg (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0041] In certain aspects, the alloy includes chromium (Cr) in an amount of up about 0.1 % (e.g., from 0 % to 0.1 %, from 0.01 % to 0.1 %, from 0.01 % to 0.07 %, or from 0.01 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, or 0.10 % Cr. In some cases, the disclosed alloy does not include Cr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0042] In certain examples, the disclosed alloy includes zinc (Zn) in an amount of up to about 3 % (e.g., from 0 % to 3 %, from 0.01 % to 3 %, from 0.01 % to 2 %, from 0.01 % to 1 %, from 0.01 % to 0.5 %, or from 0.01 % to 0.01 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.05 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %,1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95 %, 2.00 %, 2.05 %, 2.10 %,2.15 %, 2.20 %, 2.25 %, 2.30 %, 2.35 %, 2.40 %, 2.45 %, 2.50 %, 2.55 %, 2.60 %, 2.65 %,2.70 %, 2.75 %, 2.80 %, 2.85 %, 2.90 %, 2.95 %, or 3.00 % Zn. In some cases, the disclosedalloy does not include Zn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0043] In certain aspects, the alloy includes titanium (Ti) in an amount of up about 0.2 % (e.g., from 0 % to 0.2 %, from 0.01 % to 0.2 %, from 0.01 % to 0.1 %, or from 0.05 % to 0.15 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015%, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065%, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115%, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165%, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, or 0.20 % Ti. In some cases, the disclosed alloy does not include Ti (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0044] In certain aspects, the alloy includes zirconium (Zr) in an amount of up about 0.1 % (e.g., from 0 % to 0.1 %, from 0.01 % to 0.1 %, from 0.01 % to 0.07 %, or from 0.01 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, or 0.10 % Zr. In some cases, the disclosed alloy does not include Zr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0045] Optionally, the alloy can further include other minor elements, sometimes referred to as impurities, in amounts of about 0.1 % or below, 0.09 % or below, 0.08 % or below, 0.07 % or below, 0.06 % or below, 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below or each of said impurities. These impurities may include, but are not limited to, scandium (Sc), vanadium (V), nickel (Ni), yttrium (Y), hafnium (Hf), thallium (Th), gallium (Ga), tin (Sn), lead (Pb), bismuth (Bi), strontium (Sr), calcium (Ca), or combinations thereof. Accordingly, Sc, V, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, or Ca, if present, may each independently be present in an alloy in amounts of 0.1 % or below, 0.09 % or below, 0.08 % or below, 0.07 % or below, 0.06 % or below, 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below. In certain aspects, the sum of all impurities does not exceed 0.30 % (e.g., does not exceed 0.20 %, does not exceed 0.15 %, or does not exceed 0.10 %). In certain aspect, the apply compositions may be devoid of (not comprise or comprise at 0.00 %) one or more of: Sc, V, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, and Ca. All expressed in wt. % based on the total weight of the aluminum alloy.

[0046] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder

[0047] The 4xxx series aluminum alloys of the present disclosure can be fabricated from recycled content. The 4xxx series aluminum alloys can include recycled content in an amount of at least 50 % (e.g., from 50 % to 100 %, from 50 % to 95 %, from 50 % to 90 %, from 60 % to 100 %, from 60 % to 95 %, from 60 % to 90 %, from 70 % to 100 %, from 70 % to 95 %, from 70 % to 90 %, from 80 % to 99.5 %, from 90 % to 99.5 %, or from 95 % to 99.5 %) based on a total weight of material used to cast the 4xxx series aluminum alloy. For example, the alloy can include 50 %, 52 %, 54 %, 56 %, 58 %, 60 %, 62 %, 64 %, 66 %, 68 %, 70 %, 72 %, 74 %, 76 %, 78 %, 80 %, 82 %, 84 %, 86 %, 88 %, 90 %, 91 %, 92 %, 93 %, 94 %, 95 %, 96 %, 97 %, 98 %, 98.5 %, 99 %, 99.5 %, or 100 % recycled content, based on a total weight of material used to cast the 4xxx series aluminum alloy. All expressed in wt. % based on the total weight of the material used to cast the 4xxx series aluminum alloy.

[0048] Advantageously, the 4xxx series aluminum alloys described herein can be fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, preconsumer recycled material). The recycled material used to fabricate the 4xxx series aluminum alloys can include a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, preconsumer recycled material) in an amount of at least 50 % (e.g., at least 55 %, at least 60 %, at least 70 %, at least 80 %, at least 90 %, at least 95 %, from 50 % to 100 %, from 50 % to 75 %, from 70 % to 95 %, from 80 % to 100 %, or from 95 % to 100 %) based on a total weight of the recycled material. For example, the alloy can include 50 %, 52 %, 54 %, 56 %, 58 %, 60 %, 62 %, 64 %, 66 %, 68 %, 70 %, 72 %, 74 %, 76 %, 78 %, 80 %, 82 %, 84 %, 86 %, 88 %, 90 %, 91 %, 92 %, 93 %, 94 %, 95 %, 96 %, 97 %, 98 %, 98.5 %, 99 %, 99.5 %, or 100 % mixed cladded alloy recycled material, based on a total weight of the recycled material. All expressed in wt. % based on the total weight of the recycled material.

[0049] The recycled content used to fabricate the 4xxx series aluminum alloys can include one or more non-4xxx series aluminum alloys in an amount of at least 50 % (e.g., at least 55 %, at least 60 %, at least 70 %, at least 80 %, at least 90 %, at least 95 %, from 50 % to 100 %, from 50 % to 75 %, from 70 % to 95 %, from 80 % to 100 %, or from 95 % to 100 %) based on a total weight of the recycled content. For example, the alloy can include 50 %, 52 %, 54 %, 56 %, 58 %, 60 %, 62 %, 64 %, 66 %, 68 %, 70 %, 72 %, 74 %, 76 %, 78 %, 80 %, 82 %, 84 %, 86 %, 88 %, 90 %, 91 %, 92 %, 93 %, 94 %, 95 %, 96 %, 97 %, 98 %, 98.5 %, 99 %, 99.5 %, or 100 % non-4xxx series aluminum alloy, based on a total weight of the recycledmaterial. All expressed in wt. % based on the total weight of the recycled material. Examples of non-4xxx series aluminum alloys include Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, and 7xxx series aluminum alloys.

[0050] In some instances, the recycled material used to fabricate the 4xxx series aluminum alloys can include 3xxx series aluminum alloy (cladded and / or uncladded) in an amount of at least 50 % (e.g., at least 55 %, at least 60 %, at least 70 %, at least 80 %, at least 90 %, at least 95 %, from 50 % to 100 %, from 50 % to 75 %, from 70 % to 95 %, from 80 % to 100 %, or from 95 % to 100 %) based on a total weight of the recycled material. For example, the alloy can include 50 %, 52 %, 54 %, 56 %, 58 %, 60 %, 62 %, 64 %, 66 %, 68 %, 70 %, 72 %, 74 %, 76 %, 78 %, 80 %, 82 %, 84 %, 86 %, 88 %, 90 %, 91 %, 92 %, 93 %, 94 %, 95 %, 96 %, 97 %, 98 %, 98.5 %, 99 %, 99.5 %, or 100 % 3xxx series aluminum alloy, based on a total weight of the recycled content. All expressed in wt. % based on the total weight of the recycled material.

[0051] In some instances, the recycled content used to fabricate the 4xxx series aluminum alloys can include a 6xxx series aluminum alloy (cladded and / or uncladded) in an amount of at least 50 % (e.g., at least 55 %, at least 60 %, at least 70 %, at least 80 %, at least 90 %, at least 95 %, from 50 % to 100 %, from 50 % to 75 %, from 70 % to 95 %, from 80 % to 100 %, or from 95 % to 100 %) based on a total weight of the recycled material. For example, the alloy can include 50 %, 52 %, 54 %, 56 %, 58 %, 60 %, 62 %, 64 %, 66 %, 68 %, 70 %, 72 %, 74%, 76 %, 78 %, 80 %, 82 %, 84 %, 86 %, 88 %, 90 %, 91 %, 92 %, 93 %, 94 %, 95 %, 96 %,97 %, 98 %, 98.5 %, 99 %, 99.5 %, or 100 % 6xxx series aluminum alloy, based on a total weight of the recycled material. All expressed in wt. % based on the total weight of the recycled material.

[0052] In some instances, the recycled content used to fabricate the 4xxx series aluminum alloys can include 3xxx series aluminum alloy (cladded and / or uncladded) and 6xxx series aluminum alloy (cladded and / or uncladded), cumulatively, in an amount of at least 50 % (e.g., at least 55 %, at least 60 %, at least 70 %, at least 80 %, at least 90 %, at least 95 %, from 50 % to 100 %, from 50 % to 75 %, from 70 % to 95 %, from 80 % to 100 %, or from 95 % to 100 %) based on a total weight of the recycled material. For example, the alloy can include 50 %, 52 %, 54 %, 56 %, 58 %, 60 %, 62 %, 64 %, 66 %, 68 %, 70 %, 72 %, 74 %, 76 %, 78 %, 80 %, 82 %, 84 %, 86 %, 88 %, 90 %, 91 %, 92 %, 93 %, 94 %, 95 %, 96 %, 97 %, 98 %, 98.5 %, 99 %, 99.5 %, or 100 % 3xxx series aluminum alloy and 6xxx series aluminum alloy,cumulatively, based on a total weight of the recycled material. All expressed in wt. % based on the total weight of the recycled material.

[0053] The 4xxx series aluminum alloys described herein can have a solidus temperature (meaning the temperature at which the metal starts to melt) from about 525 °C to about 590 °C (e.g., from 525 °C to 550 °C, from 540 °C to 575 °C, from 550 °C to 580 °C, or from 560 °C to 590 °C). For example, the solidus temperature of the alloy can be 525 °C, 528 °C, 530 °C, 532 °C, 534 °C, 536 °C, 538 °C, 540 °C, 542 °C, 544 °C, 546 °C, 548 °C, 550 °C, 552 °C, 554 °C, 556 °C, 558 °C, 560 °C, 562 °C, 564 °C, 566 °C, 568 °C, 570 °C, 572 °C, 574 °C, 576 °C, 578 °C, 580 °C, 582 °C, 584 °C, 586 °C, 588 °C, or 590 °C.

[0054] The 4xxx series aluminum alloys described herein can have a liquidus temperature (meaning the temperature at which the material is fully molten) about 570 °C or greater (e.g., from 570 °C to 630 °C, from 570 °C to 600 °C, from 590 °C to 610 °C, from 600 °C to 615 °C, or from 610 °C to 630 °C). For example, the liquidus temperature of the alloy can be 600 °C, 602 °C, 604 °C, 606 °C, 608 °C, 610 °C, 612 °C, 614 °C, 616 °C, 618 °C, 620 °C, 622 °C, 624 °C, 626 °C, 628 °C, or 630 °C.

[0055] The 4xxx series aluminum alloys described herein that are fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material) may be used in cladding layers suitable for brazing applications.Clad Aluminum Alloy Products

[0056] Clad aluminum alloy products include a core layer (also referred to herein as a “core”) of an aluminum alloy having a first side and a second side and one or more cladding layer(s) on the first side or the second side of the core layer. In some instances, the core layer is clad on only one side (i.e., one cladding layer is present in the clad aluminum alloy product). In other instances, the core layer is clad on both sides (i.e., two cladding layers are present in the clad aluminum alloy product).

[0057] In some instances, the first side of the core layer is adjacent to and contacts a first cladding layer to form a first interface. In other words, no layers intervene between the first cladding layer and the first side of the core layer. Optionally, the clad aluminum alloy product includes a second cladding layer. In these instances, the second side of the core layer is adjacent to and contacts a second cladding layer to form a second interface (i.e., no layers intervene between the second cladding layer and the second side of the core layer). The first cladding layer and the second cladding layer can be the same chemical composition or different chemicalcompositions. The composition of the first cladding layer and / or the second cladding layer can be the 4xxx series aluminum alloys described herein that are fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material).

[0058] In some instances, a first cladding layer is on a first side of a core layer but with one or more intervening layers therebetween. Optionally, the clad aluminum alloy product includes a second cladding layer on a second side of the core layer. Optionally, the second cladding layer can be directly bonded to the core layer or can have one or more intervening layers therebetween. The first cladding layer and the second cladding layer can be the same chemical composition or different chemical compositions. The composition of first cladding layer and / or the second cladding layer can be the 4xxx series aluminum alloys described herein that are fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, preconsumer recycled material).

[0059] Clad aluminum alloy products can contain other layers (e.g., to form multilayer aluminum materials), some of which may be referred to as “interlayers,” “outer layers,” “liners,” and by other related terms. For example, clad aluminum alloy products can have 2, 3, 4, 5, 6, or more distinct layers, each having a certain function. More generally, clad aluminum alloy products can have as many layers as can be stacked and bonded together in one or more operations. In the commercial context, one possible limiting factor is the cost of production and / or scrap generated during production of clad aluminum alloy products, which can become too high with the increased number of layers for the clad aluminum alloy products to be commercially viable. In the context of clad aluminum alloy products suitable for brazing applications, one or more of the cladding layers can be the portion of the product that melts during a braze cycle. A liner can be a layer that is not expected to melt during a braze cycle and may confer sonic other benefits, such as corrosion resistance or increased strength, to the clad aluminum alloy products. An interlayer may be between the core layer and the brazing cladding layer. For example, a corrosion protection interlayer may between the core layer and the brazing cladding layer. A liner (e.g., corrosion protection liner) may also be included with the brazing cladding layer being between the liner and the core layer. One or both liners and interlayers may be present in a clad aluminum alloy product.

[0060] Regarding the composition of the core layer, any alloy designated as a “ Ixxx series” alloy, a “2xxx series” alloy, a “3xxx series” alloy, a “5xxx series” alloy, a “6xxx series” alloy, a “7xxx series” alloy, or “8xxx series” alloy including modified versions thereof is suitable foruse as the core layer. For example, in some instances, a 3xxx series alloys suitable for use as the core layer may have higher levels of Cu.

[0061] Multi-layered cladding variants of the above systems are also envisioned.

[0062] Non-limiting examples of Ixxx series aluminum alloys for use as the core layer can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, and AA1199.

[0063] Non-limiting examples of 2xxx series aluminum alloys for use as the core layer can include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055,AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095,AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098,AA2198, AA2099, and AA2199.

[0064] Non-limiting examples of 3xxx series aluminum alloys for use as the core layer can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.

[0065] Non-limiting examples of 5xxx series alloys for use as the core layer can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, 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, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, and AA5088.

[0066] Non-limiting examples of 6xxx series alloys for use as the core layer can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, 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, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, and AA6092.

[0067] Non-limiting examples of 7xxx series alloys for use as the core layer can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, 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, and AA7099.

[0068] The clad aluminum alloy products described herein may have a yield strength (Rpo.2) of from 45 MPa to 65 MPa (e.g., from about 45 MPa to about 60 MPa, from about 48 MPa to about 58 MPa, from about 50 MPa to about 60 MPa, or from about 50 MPa to about 58 MPa).

[0069] The clad aluminum alloy products described herein may have an ultimate tensile strength (Rm) of from 145 MPa to 200 MPa (e.g., from about 145 MPa to about 190 MPa, from about 150 MPa to about 190 MPa, from about 155 MPa to about 185 MPa, or from about 155 MPa to about 180 MPa).

[0070] The clad aluminum alloy products described herein may have a total elongation (as measured by DIN EN ISO 6892-1 :2017-02) (A50) of at least 15% (e.g., at least 16%, at least 17%, at least 18%, at least 19%, at least 20%, at least 21%, at least 22%, at least 23%, at least 24%, or at least 25%). In terms of ranges, the clad aluminum alloy products described herein may have an elongation of from 15% to 30% (e.g., from 16% to 28%, from 17% to 26%, from 18% to 25%, from 19% to 24%, from 20% to 23%, or from 21% to 22.5%).Methods of Preparing the Core Layers, Cladding Layers, and Clad Aluminum Alloy Products

[0071] The aluminum alloys described herein for use as the core and cladding layers can be cast using any suitable casting method. For example, the aluminum alloys can be used to cast various metallic cast products, such as billets, ingots, or strips. Methods of producing an aluminum sheet are also described herein. The aluminum alloy can be cast and then further processing steps may be performed. In some examples, the processing steps include a casting step, a pre-heating and / or a homogenizing step, one or more hot rolling steps, and one or more cold rolling steps.

[0072] For the 4xxx series aluminum alloys described herein that are fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material), the compositions described the material to be cast to produce the alloy. The balance of material up to 100 wt. % can include smelter grade aluminum and / or silicon. That is, a starting material for a casting process can comprise (i) at least 50 % recycled content (of which, is 50 wt. % is a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, preconsumer recycled material) by total weight of the recycled material) and (ii) optionally smelter grade aluminum and / or silicon to produce the 4xxx series aluminum alloy.

[0073] For example, when preparing a cladding layer comprising a 4xxx series aluminum alloy described herein, a co-cast ingot or other cast product can be processed by any means known to those of ordinary skill in the art. Optionally, the processing steps can be used to prepare sheets. Such processing steps include, but are not limited to, homogenizing, preheating, hot rolling, cold rolling, and stretching or sawing, as known to those of ordinary skill in the art. In some instances, a homogenization step and a cold rolling step are not used inpreparing a cladding layer. Advantageously, the use of recycled material may reduce the energy required to produce the cladding layer as compared to cladding layers produced principally using prime aluminum. Clad layers can also be produced by sawing from a cast ingot to final format without any rolling steps.

[0074] A hot rolling step can be performed. The ingots can then be hot rolled at a temperature between 300 °C to 500 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge of from about 3 mm to about 200 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, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature of from about 300 °C to about 450 °C. For example, the continuously cast product can be allowed to cool to a temperature of from about 325 °C to about 425 °C or from about 350 °C to about 400 °C. The continuously cast product can then be hot rolled at a temperature of from about 300 °C to about 450 °C to form a hot rolled plate, a hot rolled shate, or a hot rolled sheet having a gauge of from about 3 mm to about 200 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, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the clad alloy hot rolled product upon exit from the hot rolling mill is no more than about 470 °C, no more than about 450 °C, no more than about 440 °C, or no more than about 430 °C.

[0075] Additional processing for the plate, shate, coil, or sheet that is the cladding layer comprising a 4xxx series aluminum alloy described herein can include stretching, sawing, grinding, and the like.

[0076] When preparing a cladded aluminum product, the aluminum alloys described herein can be cast into ingots using a direct chill (DC) process, a continuous casting (CC) process, or electromagnetic casting (EMC) process. The DC casting process is performed according to standards commonly used in the aluminum industry as known to one of skill in the art. The CC casting process can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces,and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0077] The cast aluminum alloy product can be processed by any means known to those of ordinary skill in the art. Optionally, the cast aluminum alloy product can be processed, using processing steps as described herein, to prepare sheets, plates, or shates. Example processing steps include, but are not limited to, pre-heating, hot rolling, cold rolling, and / or annealing. One or more of the steps of solution heat treatment, pre-aging, and / or artificial aging may be excluded when processing the cladded aluminum product.

[0078] In a pre-heating step, a cast product may be heated to a pre-heating temperature, such as a temperature ranging from about 400 °C to about 630 °C (e.g., 400 °C to 500 °C, 450 °C to 570 °C, or 500 °C to 630 °C). For example, the cast product can 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, 600 °C, 610 °C, 620 °C, or 630 °C. In some embodiments, the heating rate to the peak metal temperature can be about 70 °C / hour or less, about 60 °C / hour or less, or about 50 °C / hour or less.

[0079] Following the pre-heating step, a hot rolling step can be performed. Prior to the start of hot rolling, the pre-heated product can be allowed to cool down to room temperature or to a desired temperature, such as from about 200 °C to about 425 °C. For example, the pre-heated product can be allowed to cool to a temperature of from about 200 °C to about 400 °C, about 250 °C to about 375 °C, about 300 °C to about 425 °C, or from about 350 °C to about 400 °C. The pre-heated product can then be hot rolled at a hot rolling start temperature, for example, from about 200 °C to about 450 °C, to produce a hot rolled intermediate product (e.g., a hot rolled plate, a hot rolled shate, or a hot rolled sheet) having a gauge from about 3 mm to about 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 anywhere in between). For example, the pre-heated product can be hot rolled to an intermediate gauge of 9.5 mm from an initial gauge of 65 mm.

[0080] During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is less than about 400° C. For example, the temperature of the hot rolled intermediate product upon exit from the hot rolling mill can be less than about 390 °C (e.g., 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 about310 °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 step can control the microstructure of the aluminum alloy. In particular, aluminum alloys produced from a high content of recycled material require critically controlled heating rates, temperatures, and other operating parameters during the hot rolling step to produce an aluminum alloy product with the mechanical properties recited herein.

[0081] A brazing clad layer (or brazing cladding or brazing cladding layer) as described herein (i.e., comprising a 4xxx series aluminum alloy described herein that is fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material)) can be attached to a core layer as described herein to form a cladded product by any means known to persons of ordinary skill in the art. For example, a brazing clad layer can be attached to a core layer by direct chill co-casting as described in, for example, U.S. Pat. Nos. 7,748,434 and 8,927, 113, both of which are hereby incorporated by reference in their entireties; fusion casting by hot and cold rolling a composite cast ingot as described in U.S. Pat. No. 7,472,740, which can be also referred to by the trade name FUSION™ (Novelis) and is hereby incorporated by reference in its entirety; or by roll bonding to achieve the required metallurgical bonding between the core and the brazing cladding; or by other methods as known to persons of ordinary skill in the art. The initial dimensions and final dimensions of the clad aluminum alloy products described herein can be determined by the desired properties of the overall final product. One skilled in the art will recognize that similar methods can be employed when there is one or more intervening layers between the brazing clad layer and the core layer.

[0082] The roll bonding process can be carried out in different manners, as known to those of ordinary skill in the art. For example, the roll-bonding process can include both hot rolling and cold rolling. Further, the roll bonding process can be a one-step process or a multi-step process in which the material is gauged down during successive rolling steps. Separate rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, solvent cleaning steps, etching steps, heating steps, cooling steps, and the like.

[0083] The cladded plate, shate, coil, or sheet can then be cold rolled using conventional cold rolling mills and technology. The cold rolled clad sheet can have a gauge of from about 0.03 mm to about 10 mm (e.g., from 0.7 mm to 6.5 mm). Optionally, the cold rolled clad sheetcan have a gauge of 0.03 mm, 0.05 mm, 0.1 mm, 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, or 10.0 mm.

[0084] The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to about 95 % (e.g., 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%, up to 85%, up to 90% or up to about 95% reduction). Optionally, an interannealing step can be performed during the cold rolling step. The interannealing step can be performed at a temperature of from about 200° C to about 450 °C (e.g., 200° C, 210 °C, 220 °C, 230 °C, 240 °C, 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, or 450 °C). In some cases, the interannealing step comprises multiple processes. In some non-limiting examples, the interannealing step includes heating the cladded plate, shate, coil, or sheet to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, the cladded plate, shate, coil, or sheet can be heated to about 410 °C for about 1 hour and then heated to about 330 °C for about 2 hours.Uses and Applications

[0085] Uses and applications of the brazing clad aluminum alloys described herein (i.e., 4xxx series aluminum alloys described herein that are fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material)) are included within the scope of the present invention, as are products, forms, apparatuses, and similar things fabricated with or comprising the brazing clad aluminum alloys described herein. The processes for fabricating, producing, or manufacturing such products, forms, apparatuses, and similar things are also included within the scope of the present invention.

[0086] Brazing, as incorporated into the embodiments of the present invention, includes, but is not limited to, vacuum brazing, controlled atmosphere brazing (CAB), Ni plating processes, flame brazing, induction brazing, laser brazing, open atmosphere brazing or molten salt brazing.

[0087] To be suitable for CAB brazing, the 4xxx series aluminum alloys described herein should contain less than or equal to 0.3 wt. % Mg, unless special fluxes are used to limit or eliminate the formation of the KMgF2 needles. To be suitable for vacuum brazing, the 4xxx series aluminum alloys described herein should contain from approximately 0.2 wt. % to 2 wt.% Mg. For example, the 4xxx series aluminum alloys described herein may contain up to approximately 0.5 wt. % Mg. Mg content in the 4xxx series aluminum alloys described herein may be unspecified in some embodiments of the present invention, although it may still be present in the 4xxx series aluminum alloys.

[0088] CAB refers to a batch, semi-continuous, or continuous brazing process which utilizes an inert atmosphere, for example, nitrogen, argon or helium in the brazing of alloy articles. In CAB, the brazing atmosphere in the furnace during the brazing operation is at about regular atmospheric pressure, although a slight under-pressure (for example working at a pressure of 0.1 bar or more) or having a slight over-pressure can be used to facilitate the control of the inert atmosphere and to prevent an influx of oxygen containing gas into the brazing furnace.

[0089] Vacuum brazing can be carried out at relatively low atmosphere pressure in the order of about 1 x 10'4mbar or less (e.g., 1 x 10'5mbar or less or 1 x 10'6mbar or less).

[0090] One exemplary product is a heat exchanger. Heat exchangers are produced by the assembly of parts comprising tubes, plates, fins, headers, and side supports to name a few. For example, a radiator is assembled from tubes, fins, headers, and side supports. Parts of the heat exchanger can be clad with a brazing cladding layer on one or two sides. Once assembled, a heat exchanger unit is secured by banding or such device to hold the unit together through fluxing and brazing. Brazing is commonly affected by passing the unit through a tunnel furnace. Brazing can also be performed by dipping in molten salt or in a batch or semi-batch process. The unit is heated to a brazing temperature between about 570 °C and about 620 °C, soaked at an appropriate temperature until joints are created by capillary forces and then cooled below the solidus of the brazing cladding. Heating rate is dependent on the furnace type and the size of the heat exchanger produced.

[0091] Some other exemplary products that can be made with the alloys of the present invention are described and shown in U.S. Pat. No. 8,349,470. Some examples of such products are an evaporator plate, an evaporator, a radiator, a heater, a heater core, a condenser, condenser tubes, various tubes and pipes, a manifold, and some structural features, such as side supports. The uses of the 4xxx series aluminum alloys described herein are not limited to the processes that involve brazing cladding alloys onto core alloys or interlayer alloys. For example, the 4xxx series aluminum alloys described herein can be produced for filler rings made from drawn wire. In another example, the 4xxx series aluminum alloys described herein produced in sheet form can be used as filler shim.

[0092] Advantageously, the chemistry of the 4xxx alloys described herein may improve the corrosion resistance of the brazing clad layer because of the OCP corrosion values the brazing clad layer and the core layer may be closer. Consequently, the OCP corrosion profile is more balanced with less of a drop in OCP corrosion values from the core layer to the brazing clad layer. This may be particularly advantageous at mitigating a corrosion pathway from the outside to the inside of heat exchangers with stacked plate or shell designs which are often used for oil coolers, charge air coolers, and chillers.ILLUSTRATIVE ASPECTS

[0093] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4 ”).

[0094] Aspect 1 is a 4xxx series aluminum alloy comprising: 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum; and wherein the 4xxx series aluminum alloy comprises at least 50 wt. % recycled content, and wherein at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material).

[0095] Aspect 2 is the 4xxx series aluminum alloy of any previous or subsequent aspect, wherein the recycled content comprises a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, or a combination thereof.

[0096] Aspect 3 is the 4xxx series aluminum alloy of any previous or subsequent aspect, wherein the 4xxx series aluminum alloy comprises at least 70 wt. % recycled material, and wherein at least 55 wt. % of the recycled material is the mixed cladded alloy recycled material.

[0097] Aspect 4 is the 4xxx series aluminum alloy of any previous or subsequent aspect comprising: 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.2 wt. % to 1 wt. % copper, 0.3 wt. % to 1.9 wt. % manganese, 0.01 wt. % to 2 wt. % magnesium, 0.01 wt. % to 0.1 wt. % chromium, 0.01 wt. % to 3 wt. % zinc, 0.01 wt. % to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum.

[0098] Aspect 5 is the 4xxx series aluminum alloy of any previous or subsequent aspect comprising: 6 wt. % to 11 wt. % silicon, 0.2 wt. % to 0.5 wt. % iron, 0.2 wt. % to 1 wt. % copper, 0.4 wt. % to 1.25 wt. % manganese, 0.01 wt. % to 2 wt. % magnesium, 0.01 wt. % to 0.07 wt. % chromium, 0.01 wt. % to 1 wt. % zinc, 0.01 wt. % to 0.15 wt. % titanium, up to 0.05 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum.

[0099] Aspect 6 is a cladded aluminum sheet comprising: a core layer comprising an aluminum alloy; and a brazing cladding layer on one side of the core layer or on both sides of the core layer, wherein the brazing cladding layer is fabricated from the 4xxx series aluminum alloy of any previous or subsequent aspect.

[0100] Aspect 7 is the cladded aluminum sheet of aspect 6, wherein the core layer is fabricated from a 3xxx series aluminum alloy or a 6xxx series aluminum alloy.

[0101] Aspect 8 is the cladded aluminum sheet of any of aspects 6-7, further comprising an interlayer between the core layer and the brazing cladding layer.

[0102] Aspect 9 is the cladded aluminum sheet of any of aspects 6-8, further comprising a corrosion protection liner and / or a corrosion protection interlayer.

[0103] Aspect 10 is a process for preparing the cladded aluminum sheet of any of aspects 6-9, the process comprising: fusion casting the core layer and the brazing cladding layer.

[0104] Aspect 11 is a process comprising joining by brazing at least one first aluminum alloy form fabricated from the 4xxx series aluminum alloy of any previous or subsequent aspect with a second aluminum alloy form.

[0105] Aspect 12 is a product fabricated by a process comprising the process of aspect 11.

[0106] Aspect 13 is the product of aspect 12, wherein the product is a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and / or a manifold or assembly thereof.

[0107] Aspect 14 is a process of joining two or more aluminum forms by brazing, wherein at least one of the two or more aluminum forms is a brazing cladding layer fabricated from the 4xxx series aluminum alloy of any previous or subsequent aspect, the process comprising: assembling and securing the two or more aluminum forms together; heating the two or more aluminum forms to a brazing temperature until joints are created among the two or more aluminum forms by capillary forces; and cooling the two or more aluminum forms below solidus of the brazing cladding layer.

[0108] Aspect 15 is the process of aspect 14, wherein the brazing temperature is from 570 °C to 620 °C.

[0109] Aspect 16 is the process of any of aspects 14-15, wherein the brazing is a controlled atmosphere brazing, and wherein the 4xxx series aluminum alloy comprises up to 0.3 wt. % magnesium.

[0110] Aspect 17 is the process of any of any of aspects 14-16, wherein the brazing is a vacuum brazing, and wherein the 4xxx series aluminum alloy comprises from 0.2 wt. % to 1.5 wt. % magnesium.

[0111] Aspect 18 is a process for preparing an aluminum material comprising a core layer and a brazing cladding layer, the process comprising: casting a 4xxx series aluminum alloy using at least 50 wt. % recycled content, based on a total weight of materials used for casting, wherein at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material), and wherein the 4xxx series aluminum alloy comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum; rolling the 4xxx series aluminum alloy to a required thickness, thus producing the brazing cladding layer; assembling the brazing cladding layer onto at least one side of the core layer; and hot roll bonding the brazing cladding layer onto the core layer.

[0112] Aspect 19 is the process of aspect 18, wherein the casting also uses smelter grade aluminum and / or silicon.

[0113] Aspect 20 is the process of any of aspects 18-19, wherein the recycled content comprises a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, or a combination thereof.EXAMPLES

[0114] Example 1. A cladded aluminum sheet was prepared with aluminum alloys according to Table 4 for the core layer and the brazing cladding layer on one side of the core layer. The aluminum alloy of the brazing cladding layer had a 94% recycled content. The cladded aluminum sheet was in an O-temper and had a total thickness of about 0.6 mm with about 10% of the thickness being from the brazing cladding layer.Table 4* with inevitable impurities

[0115] Before brazing, the earing was 2.5% and cupping was 7.4 mm. The mechanical properties of the cladded aluminum sheet are reported in Table 5. The yield strength (Rpo.2) and tensile strength (Rm) were measured according to ISO 6892-1 (2016). The elongation at fracture (or total elongation, A50) was measured according to DIN EN ISO 6892-1 :2017-02.Table 5

[0116] An AA3003 angle (FIG. 1) was joined to the cladded aluminum sheet with a defined T-t-profile and flux load of ~ 6 g / m2and in a 10 ppm residual oxygen controlled atmosphere.Different brazing cycles per Table 6 were tested. The braze joint height was analyzed using cross-sections at defined positions 13 mm and 26 mm from the tip of the angle. Samples were ground and polished for measuring height of braze joint at 8 positions, which were averaged for the reported braze joint height. FIG. 2 is a light microscope image of the braze joint after 3 minutes at 600°C.Table 6

[0117] Example 2. A cladded aluminum sheet was prepared with aluminum alloys according to Table 7 for the core layer and the brazing cladding layer on one side of the core layer. The aluminum alloy of the brazing cladding layer had a 94% recycled content. The cladded aluminum sheet was in an O-temper and a total thickness of about 0.6 mm with about 10% of the thickness being from the brazing cladding layer.Table 7* with inevitable impurities

[0118] Before brazing, the earing was 3.6% and cupping was 8.2 mm. The mechanical properties of the cladded aluminum sheet are reported in Table 8.Table 8

[0119] An AA3003 angle, same as Example 1, was joined to the cladded aluminum sheet with a defined T-t-profile and flux load of ~ 6 g / m2and in a 10 ppm residual oxygen controlled atmosphere. Different brazing cycles per Table 9 were tested. The braze joint height was analyzed using cross-sections at defined positions 13 mm and 26 mm from the tip of the angle. Samples were ground and polished for measuring height of braze joint at 8 positions, which were averaged for the reported braze joint height. FIG. 3 is light microscope image of the braze joint after 3 minutes at 600°C.Table 9

[0120] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to beexhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

WHAT IS CLAIMED IS:

1. A 4xxx series aluminum alloy comprising:6 wt. % to 13 wt. % silicon,0.1 wt. % to 0.7 wt. % iron,0.1 wt. % to 1.5 wt. % copper,0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum; and wherein the 4xxx series aluminum alloy comprises at least 50 wt. % recycled content, and wherein at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material.

2. The 4xxx series aluminum alloy of claim 1, wherein the recycled content comprises a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, or a combination thereof.

3. The 4xxx series aluminum alloy of claim 1, wherein the 4xxx series aluminum alloy comprises at least 70 wt. % recycled material, and wherein at least 55 wt. % of the recycled material is the mixed cladded alloy recycled material.

4. The 4xxx series aluminum alloy of claim 1 comprising:6 wt. % to 13 wt. % silicon,0.1 wt. % to 0.7 wt. % iron,0.2 wt. % to 1 wt. % copper,0.3 wt. % to 1.5 wt. % manganese,0.01 wt. % to 2 wt. % magnesium,0.01 wt. % to 0.1 wt. % chromium,0.01 wt. % to 3 wt. % zinc,0.01 wt. % to 0.2 wt. % titanium,up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum.

5. The 4xxx series aluminum alloy of claim 1 comprising:6 wt. % to 11 wt. % silicon,0.2 wt. % to 0.5 wt. % iron,0.2 wt. % to 1 wt. % copper,0.4 wt. % to 1.25 wt. % manganese,0.01 wt. % to 2 wt. % magnesium,0.01 wt. % to 0.07 wt. % chromium,0.01 wt. % to 1 wt. % zinc,0.01 wt. % to 0.15 wt. % titanium, up to 0.05 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum.

6. A cladded aluminum sheet comprising: a core layer comprising an aluminum alloy; and a brazing cladding layer on one side of the core layer or on both sides of the core layer, wherein the brazing cladding layer is fabricated from the 4xxx series aluminum alloy of claim 1.

7. The cladded aluminum sheet of claim 6, wherein the core layer is fabricated from a 3xxx series aluminum alloy or a 6xxx series aluminum alloy.

8. The cladded aluminum sheet of claim 6, further comprising an interlayer between the core layer and the brazing cladding layer.

9. The cladded aluminum sheet of claim 6, further comprising a corrosion protection liner and / or a corrosion protection interlayer.

10. A process for preparing the cladded aluminum sheet of claim 6, the process comprising:fusion casting the core layer and the brazing cladding layer.

11. A process comprising joining by brazing at least one first aluminum alloy form fabricated from the 4xxx series aluminum alloy of claim 1 with a second aluminum alloy form.

12. A product fabricated by a process comprising the process of claim 11.

13. The product of claim 12, wherein the product is a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and / or a manifold or assembly thereof.

14. A process of joining two or more aluminum forms by brazing, wherein at least one of the two or more aluminum forms is a brazing cladding layer fabricated from the 4xxx series aluminum alloy of claim 1, the process comprising: assembling and securing the two or more aluminum forms together; heating the two or more aluminum forms to a brazing temperature until joints are created among the two or more aluminum forms by capillary forces; and cooling the two or more aluminum forms below solidus of the brazing cladding layer.

15. The process of claim 14, wherein the brazing temperature is from 570 °C to 620 °C.

16. The process of claim 14, wherein the brazing is a controlled atmosphere brazing, and wherein the 4xxx series aluminum alloy comprises up to 0.3 wt. % magnesium.

17. The process of claim 14, wherein the brazing is a vacuum brazing, and wherein the 4xxx series aluminum alloy comprises from 0.2 wt. % to 1.5 wt. % magnesium.

18. A process for preparing an aluminum material comprising a core layer and a brazing cladding layer, the process comprising: casting a 4xxx series aluminum alloy using at least 50 wt. % recycled content, based on a total weight of materials used for casting,wherein at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material, and wherein the 4xxx series aluminum alloy comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.3 wt. % of impurities, and aluminum; rolling the 4xxx series aluminum alloy to a required thickness, thus producing the brazing cladding layer; assembling the brazing cladding layer onto at least one side of the core layer; and hot roll bonding the brazing cladding layer onto the core layer.

19. The process of claim 18, wherein the casting also uses smelter grade aluminum and / or silicon.

20. The process of claim 18, wherein the recycled content comprises a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, or a combination thereof.

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