Aluminum alloys, articles formed from aluminum alloys, clad composites comprising aluminum alloys, and methods of forming articles

Abstract

Aluminum alloys, articles formed from aluminum alloys, clad composites comprising aluminum alloys, and methods of forming articles are disclosed. One embodiment of the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2.0 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and a copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1.

Description

TITLEALUMINUM ALLOYS, ARTICLES FORMED FROM ALUMINUM ALLOYS, CLAD COMPOSITES COMPRISING ALUMINUM ALLOYS,AND METHODS OF FORMING ARTICLESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 623,444, which was filed on January 22, 2024, the contents of which is hereby incorporated by reference into this specification.FIELD OF USE

[0002] The present disclosure relates to aluminum alloys, articles formed from aluminum alloys, clad composites comprising aluminum alloys, and methods of forming articles.BACKGROUND

[0003] Various apparatus, such as, for example, heat exchangers, may be formed from stacked specially designed metal plates, such as, for example, brazing sheets. Plate-type heat exchangers function by circulating two fluids (e.g., liquid, refrigerant, or combinations thereof) on opposite sides of a plate, allowing heat exchange between the fluids. There are challenges associated with designing acceptable brazing sheets and sourcing feedstock materials for producing the brazing sheets.SUMMARY

[0004] One non-limiting aspect according to the present disclosure is directed to an aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2.0 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum. A copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1. As used in the present disclosure, the Cueqof an alloy is calculated by the following equation:CUeq = [Cu] - (1.9 • [Zn])wherein [Cu] and [Zn], respectively, are the weight percentages of copper and of zinc in the aluminum alloy.

[0005] An additional non-limiting aspect according to the present disclosure is directed to a structural element comprising all or a portion of a sheet product including an aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2.0 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum. A copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1.

[0006] An additional non-limiting aspect according to the present disclosure is directed to an article comprising a structural element comprising all or a portion of a sheet product including an aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2.0 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum. A copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1.

[0007] Yet a further non-limiting aspect according to the present disclosure is directed to a method for manufacturing an aluminum alloy. The method comprises melting a charge comprising at least 20% by weight scrap material from post-consumer brazing scrap and a non-scrap feed material. The method further comprises forming an ingot from the molten charge.

[0008] It is understood that the inventions disclosed and described in this specification are not limited to the aspects summarized in this Summary. The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of various non-limiting and non-exhaustive aspects according to this specification.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and advantages of the examples, and the manner of attaining them, will become more apparent, and the examples will be better understood, by reference to the following description taken in conjunction with the accompanying drawing, wherein:

[0010] FIG. l is a schematic side elevational view of a first non-limiting embodiment of a clad composite according to the present disclosure;

[0011] FIG. 2 is a schematic side elevational view of a second non-limiting embodiment of a clad composite according to the present disclosure;

[0012] FIG. 3 is a schematic side elevational view of a third non-limiting embodiment of a clad composite according to the present disclosure;

[0013] FIG. 4 is a schematic side elevational view of a fourth non-limiting embodiment of a clad composite according to the present disclosure;

[0014] FIG. 5 is a schematic side elevational view of a fifth non-limiting embodiment of a clad composite according to the present disclosure; and

[0015] FIG. 6 is a flow chart illustrating a non-limiting embodiment of a method for forming an article according to the present disclosure.

[0016] The exemplifications set out herein illustrate certain embodiments, in one or more forms, and such exemplifications are not to be construed as limiting the scope of the appended claims in any manner.DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0017] Various embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed alloys, articles, and methods. The various embodiments described and illustrated herein are non-limiting and non-exhaustive. Thus, an invention is not limited by the description of the various nonlimiting and non-exhaustive embodiments disclosed herein. Rather, the invention is defined solely by the claims. The features and characteristics illustrated and / or described in connection with various embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any features or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, the applicant reserves the right to amend the claims to affirmatively disclaim features or characteristics that may be present in the prior art. Thevarious embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the features and characteristics as variously described herein.

[0018] Any references herein to “various embodiments”, “some embodiments”, “one embodiment”, “an embodiment”, “a non-limiting embodiment”, or like phrases mean that a particular feature, structure, step, or characteristic described in connection with the example is included in at least one embodiment. Thus, appearances of the phrases “various embodiments”, “some embodiments”, “one embodiment”, “an embodiment”, “a non-limiting embodiment”, or like phrases in the specification do not necessarily refer to the same embodiment. Furthermore, the particular described features, structures, steps, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, steps, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, steps, or characteristics of one or more other embodiments, without limitation. Such modifications and variations are intended to be included within the scope of the present embodiments.

[0019] Various non-limiting embodiments of alloys discussed in connection with the present disclosure optionally include intentional additions of incidental elements that may, for example, aid in production of the alloy and / or improve one or more properties or characteristics of the alloy. For example, certain non-limiting embodiments of alloys according to the present disclosure may include intentional incidental additions of one or more grain refining elements and / or one or more deoxidizing elements. In various nonlimiting embodiments, the total concentration of incidental elements in alloys according to the present disclosure preferably does not exceed 1 weight percent, based on the total weight of the alloy, and the concentration of any single incidental element preferably does not exceed 0.2 weight percent, based on the total weight of the alloy.

[0020] Various non-limiting embodiments of alloys discussed in connection with the present disclosure may include impurities. As used herein, “impurities” are elements or other materials that may be present in relatively minor concentrations in alloys according to the present disclosure but that are not intentionally added to enhance production or affect properties or characteristics of the alloy. For example, impurities in the alloys according to the present disclosure may be present in minor concentrations due to, for example, the unavoidable or unintentional presence of the impurities in feed materials; incorporation fromthe local atmosphere during melting, refining, or other processing; or contamination by contact with processing equipment. In various non-limiting embodiments, the total concentration of impurities in alloys discussed in the present disclosure preferably does not exceed 0.15 weight percent, based on the total weight of the alloy, and the concentration of any single impurity preferably does not exceed 0.05 weight percent based on the total weight of the alloy.

[0021] Brazing sheets typically include alloying elements that would be of value if they can be separated from scrap brazing sheets or from used or scrapped articles of manufacture formed from or including brazing sheets. Brazing sheets typically include multiple layers, each having its own compositional specifications. It can be challenging to separate layers of a brazing sheet, remove an individual alloying element from a brazing sheet, or separate a layer from an article including or formed from a brazing sheet. As a result, the brazing sheets or articles may have to be recycled as a whole, without first isolating the layers or regions in which desired elements are present. Certain alloying elements in the scrap brazing sheets or scrap articles may be present in concentrations undesirable for use as recycled feed materials in the production of certain aluminum alloy sheets to be incorporated into brazing sheets. For example, some alloying elements may be present in the brazing sheets or scrap articles in concentrations that will adversely affect characteristics of a brazing sheet core layer such as, for example, corrosion resistance, grain size, and / or other microstructural characteristics of the core layer.

[0022] The present inventor has determined that a balance of chemistry modifications from elements present in scrap material with additional purposeful elemental additions can provide desired properties in aluminum alloys. The present disclosure provides an aluminum alloy that can be produced using feed material comprising scrap material, while maintaining acceptable or superior formability, corrosion resistance, brazeability, strength, and / or diffusion resistance in the aluminum alloy. Embodiments of an aluminum alloy according to the present disclosure can comprise, in weight percentages based on total weight of the aluminum alloy, 0.3 to 1.1 silicon, 0.3 to 2.0 manganese, 0.2 to 1.0 zinc, 0.4 to 2.0 copper, 0 to 0.7 iron, 0 to 0.8 magnesium, 0 to 0.25 titanium, 0 to 0.3 chromium, 0 to 0.25 zirconium, optionally, incidental elements, impurities, and aluminum. A copper equivalent value (Cueq) of the aluminum alloy can be in a range of 0 to 1.

[0023] As used herein, the term “core layer” refers to a substrate layer of a clad composite. In various non-limiting embodiments, a “core layer” can be disposed substantially in the center of a clad composite. However, the position of the core layer in a clad composite according to the present disclosure is not limited to the center of the clad composite. Each of the faces (i.e., sides) of the core layer may or may not be covered with another layer of the clad composite and, for example, the core layer of the clad composite may be partially or fully exposed on one side of the clad composite. Accordingly, in various non-limiting embodiments, the core layer of embodiments of a clad composite according to the present disclosure can be fully covered on both of the core layer’s faces by other layers of the clad composite, can have at least one face that is at least partially exposed, or can have at least one face that is fully exposed.

[0024] Referring to FIG. 1, a clad composite 100 is provided. The clad composite 100 comprises a core layer 102 and a first layer 104. In various non-limiting embodiments, the core layer 102 and the first layer 104 are bonded (e.g., roll bonded) together to form the clad composite 100. In various non-limiting embodiments, the first layer 104 can be a brazing layer, an interliner liner, or a waterside liner. Although the clad composite 100 illustrated in FIG. 1 includes two layers, other embodiments of a clad composite can comprise one or more additional layers. For example, embodiments of a clad composite according to the present disclosure may have three layers as illustrated in FIGs. 2 and 5, four layers as illustrated in FIG. 4, or five layers as illustrated in FIG. 3. In various non-limiting embodiments, the clad composite 100 can be a brazing sheet.

[0025] Referring to FIG. 1, the core layer 102 of the clad composite 100 comprises a first aluminum alloy, such as, for example, a 3XXX series aluminum alloy (e.g., a 3003 aluminum alloy). The first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 0.3 to 1.1 silicon, such as, for example, 0.4 to 1.1 silicon, 0.5 to 1.1 silicon, 0.6 to 1.1 silicon, 0.5 to 1 silicon, 0.5 to 9 silicon, 0.6 to 0.84 silicon, or 0.72 to 0.81 silicon. The silicon in the first aluminum alloy may be derived from scrap material included in the feed material from which the first aluminum alloy is produced.

[0026] The first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 0.3 to 2.0 manganese, such as, for example, 0.4 to 1.9 manganese, 0.6 to 1.8 manganese, 0.8 to 1.7 manganese, 0.9 to 1.6 manganese, 1.0 to 1.5 manganese, 1.1 to 1.4 manganese, or 1.17 to 1.33 manganese. The manganese in the firstaluminum alloy may be derived from scrap material included in the feed material from which the first aluminum alloy is produced.

[0027] The first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 0.2 to 1.0 zinc, such as, for example, 0.2 to 0.8 zinc, 0.2 to 0.6 zinc, 0.2 to 0.5 zinc, 0.2 to 0.4 zinc, or 0.2 to 0.3 zinc. The zinc in the first aluminum alloy may be derived from scrap material included in the feed material from which the first aluminum alloy is produced.

[0028] It was discovered that maintaining a particular balance of certain elements in the first aluminum alloy can allow the aluminum alloy to be produced from a feed material including a substantial amount of scrap material, while still exhibiting desirable properties. For example, corrosion potential of the first aluminum alloy can be affected by the concentration of silicon, copper, manganese, magnesium, and zinc in solution in the aluminum matrix phase of the first aluminum alloy. In the O-temper condition of a product comprising the first aluminum alloy, the manganese concentration of the first aluminum alloy may not significantly affect the corrosion potential, as most solute manganese is removed from solution (e.g., as AkMn) during homogenization, reheat, and annealing, or by the presence of silicon, which forms a-AlMnSi. The silicon and magnesium concentration of the first aluminum alloy also may not significantly affect the corrosion potential of the first aluminum alloy as the concentration of the respective elements present in the solute is limited.

[0029] It was discovered that zinc and copper may have a significant effect on the corrosion potential of the first aluminum alloy and a suitable balance therebetween can result in a suitable corrosion potential for the first aluminum alloy. For example, when the copper concentration in the first aluminum alloy is no greater than 1 percent by weight, zinc is approximately 1.9 times more anodic than copper. Thus, a Cueqcan be calculated for the first aluminum alloy by the following equation:CUeq=[Cu] — (1.9 • [Zn]) wherein [Cu] and [Zn], respectively, are the weight percentages of copper and of zinc in the first aluminum alloy. A corrosion potential of the first aluminum alloy can be desirable when the Cueqvalue is 0 or greater than 0. In various non-limiting embodiments, to provide a desirable corrosion potential the Cueqvalue of the first aluminum alloy can be in a range of 0to 1, such as, for example, 0.05 to 1, 0 to 0.9, 0 to 0.5, 0.05 to 0.5, 0 to 0.2, 0.05 to 0.2, 0.12 to 0.18, or 0.14 to 0.16.

[0030] Copper may be added intentionally to feed material from which the first aluminum alloy is produced to account for zinc content in scrap material included in the feed material. In various embodiments, the first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 0.4 to 2.0 copper, such as, for example, 0.4 to 1.5 copper, 0.4 to 1.2 copper, 0.4 to 1.1 copper, or 0.4 to 1.0 copper.

[0031] In various embodiments, the first aluminum alloy also can comprise one or more of , iron, magnesium, and titanium. In certain embodiments the first aluminum alloy can comprise 0 to 0.7 iron, such as, for example, 0.05 to 0.7 iron, 0.2 to 0.7 iron, 0.3 to 0.7 iron, 0.4 to 0.6 iron, or 0.45 to 0.55 iron. In certain embodiments the first aluminum alloy can comprise 0 to 0.8 magnesium, such as, for example, 0 to 0.7 magnesium, 0 to 0.4 magnesium, 0 to 0.1 magnesium, 0 to 0.05 magnesium, or 0 to 0.48 magnesium. In certain embodiments the first aluminum alloy can comprise 0 to 0.25 titanium, such as, for example, 0.03 to 0.2 titanium, 0.05 to 0.2 titanium, 0.1 to 0.2 titanium, or 0.115 to 0.15 titanium.

[0032] Certain non-limiting embodiments of the first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2.0 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum. In various non-limiting embodiments, the first aluminum alloy comprises, in weight percentages based on total weight of the first aluminum alloy: 0.6 to 0.84 silicon; 1.1 to 1.4 manganese; 0.2 to 0.4 zinc; 0.4 to 1.0 copper; 0.4 to 0.6 iron; 0 to 0.05 magnesium; 0.1 to 0.2 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum.

[0033] The chemistry of the core layer (e.g., core layer 102 of the composites shown in FIGs. 1-5) of a brazing sheet or other clad composite material according to the present disclosure can be modified to include a corrosion protection mechanism in addition or as an alternative to a brown band. For example, the core layer can be modified to include a concentration of copper that imparts galvanic protection to the core layer 102. A copper concentration that is too high could undesirably affect properties of the core layer 102. In various embodiments, the core layer 102 can comprise a weight ratio of copper to manganese in the first aluminumalloy that is no greater than 1, such as, for example, no greater than 0.9, or no greater than 0.8.

[0034] The first aluminum alloy can be formed by melting a feed material including a single or multiple materials, and forming an ingot from the molten feed material. For example, the first aluminum alloy can be formed from a feed material comprising, for example, at least 10% by weight scrap material, such as, for example, at least 20% by weight scrap material, at least 30% by weight scrap material, at least 40% by weight scrap material, or at least 50% by weight scrap material. The remainder of the material in the feedstock can be materials that are non-scrap materials, such as, for example, pure materials (e.g., primary aluminum, such as, for example, grade P1020) and, optionally, hardeners. The amount of scrap material included may be balanced based on the concentration of zinc or other alloying elements in the scrap material so as not to unacceptably affect properties of the resulting aluminum alloy. For example, the amounts of scrap material and the other, non-scrap material(s) included in a charge melted to form an ingot of the first aluminum alloy may be selected such that the first aluminum alloy includes no greater than 1.0 wt% zinc by weight, based on the total weight of the first aluminum alloy. The scrap material can be, for example, pre-consumer waste from the production of brazing sheets or components thereof (e.g., revert) and / or post-consumer waste obtained from a third party source. The scrap material can comprise, for example, scrap brazing sheets, used or scrapped articles of manufacture formed from or including brazing sheets, and / or scrap material from another source (e.g., industrial, automotive, packaging, can, sheet). The first aluminum alloy ingot can be formed into a sheet suitable for incorporation into a clad composite (e.g., a brazing sheet) or another desired shape. The scrap material can comprise, in weight percentages based on total weight of the scrap materials, at least 0.1 zinc, at least 0.2 zinc, at least 0.3 zinc, at least 0.4 zinc, or at least 0.5 zinc.

[0035] Referring again to FIG. 1, in embodiments in which the clad composite 100 comprises a brazing layer, the clad composite 100 can be subjected to brazing as a step in a production process to form an article of manufacture. For example, in a brazing step, an assembly comprising the clad composite 100 and a part are heated to a temperature at least as high as the melting temperature of the brazing layer so that the brazing layer melts and flows to wet a surface of the part and subsequently solidifies to form a suitable braze joint between the clad composite and the part. In various embodiments, the temperature to which the assembly isheated in the brazing step can be sufficiently high to dissolve soluble phases in the clad composite 100. In certain embodiments, during brazing the assembly is heated to a temperature in a range of 590°C to 610°C. In various embodiments, the heated assembly is cooled quickly, which can minimize the precipitation of undesirable soluble phases.

[0036] During brazing, it can be desirable that the core layer 102 does not melt such that the core layer 102 retains desired strength, structural integrity, and / or corrosion performance. For example, in various embodiments the core layer 102 can have a core layer solidus temperature greater than the brazing temperature to which the clad composite 100 is subjected. For example, in certain embodiments the core layer 102 can have a core layer solidus temperature of at least 600°C, such as, for example, at least 605°C, at least 610°C, or at least 615°C.

[0037] In various non-limiting embodiments, the core layer 102 can be homogenized and O- temper. As used herein, O-temper has the meaning provided in ANSI H35.1 / H35.1(M)-2017.

[0038] In various embodiments, the brazing layer can comprise a second aluminum alloy, such as, for example, a 4XXX series aluminum alloy. In various non-limiting embodiments, the second aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy: 5 to 15 silicon; 0 to 2 magnesium; 0 to 1 iron; 0 to 3 zinc; 0 to 2 copper; 0 to 1 manganese; 0 to 0.3 bismuth; optionally, incidental elements; impurities; and aluminum. The brazing layer exhibits a brazing layer solidus temperature that is lower than the core layer solidus temperature, such as, for example, at least 5°C lower, at least 10°C lower, at least 15°C lower, at least 20°C lower, at least 25°C lower, or at least 30°C lower than the core layer solidus temperature. Ensuring that the brazing layer solidus temperature is sufficiently lower than the core layer solidus temperature can enable a brazing process wherein heating the clad composite 100 to the brazing temperature melts the brazing layer, while the core layer remains substantially solid.

[0039] Referring again to FIG. 1, the thickness of each layer in the clad composite 100 can be configured based on the desired structural properties of the article (e.g., a heat exchanger) that is to be produced from or that is to incorporate the clad composite 100. For example, in various non-limiting embodiments, the core layer 102 can comprise a first thickness, ti, that can be in a range of 60% to 97% of a total thickness (z.e., ttotai) of the clad composite 100. In various non-limiting embodiments, the first layer 104 can comprise a second thickness, t2,that is in a range of 3% to 20% of the total thickness (ttotai) of the clad composite 100. In various non-limiting embodiments, the first thickness, ti, is greater than the second thickness, t2. In certain non-limiting embodiments, the total thickness (ttotai) of the clad composite 100 is in a range of 100 pm to 5 mm, such as, for example, in a range of 200 pm to 1 mm.

[0040] In various non-limiting embodiments, a clad composite according to the present disclosure may comprise one or more layers in addition to a core layer. For example, referring to the non-limiting embodiment shown schematically in FIG. 2, clad composite 200 comprises the core layer 102, a brazing layer 204 disposed on a first face (side) 102a of the core layer 102, and a layer 206 disposed on a second face 102b of the core layer 102 opposite a first face 102a of the core layer 102. In various embodiments, the layer 206 may be a second brazing layer configured as described above, or the layer 206 can be a waterside liner. In various non-limiting embodiments, the core layer 102, the brazing layer 204, and the layer 206 are bonded (e.g., roll bonded) together to form the clad composite 200.

[0041] In embodiments in which the layer 206 is a second brazing layer, the layer 206 and the brazing layer 204 may have the same composition or may have different compositions.

[0042] In embodiments in which the layer 206 is a waterside liner, the waterside liner can provide corrosion protection to the clad composite 200 and can be in contact with coolant during operation of an article comprising all or a portion of the clad composite 200. In certain embodiments, the waterside liner can comprise a third aluminum alloy comprising, in weight percentages based on total weight of the third aluminum alloy: 0.5 to 12 zinc; 0.1 to 1.2 silicon; 0 to 1 iron; 0 to 0.3 copper; 0 to 1.5 manganese; 0 to 0.6 magnesium; 0 to 0.2 titanium; 0 to 0.2 zirconium; optionally incidental elements; impurities; and aluminum.

[0043] In various non-limiting embodiments, a clad composite according to the present disclosure may comprise one or two interliner layers. Referring to the non-limiting embodiment shown schematically in FIG. 3, for example, clad composite 300 comprises the core layer 102, the brazing layer 204, the layer 206, an interliner layer 308, and an interliner layer 310. The interliner layer 308 is intermediate the brazing layer 204 and the core layer 102, and the interliner layer 310 is intermediate the layer 206 and the core layer 102. In various non-limiting embodiments, the core layer 102, the brazing layer 204, the layer 206, the interliner layer 308, and the interliner layer 310 are bonded (e.g., roll bonded) together to form the clad composite 300.

[0044] Each of the interliner layers 308 and 310 of the clad composite 300 individually comprises a third aluminum alloy, which can be, for example, a 1XXX series aluminum alloy, a 3XXX series aluminum alloy, or a 7XXX series aluminum alloy. The compositions of the interliner layers 308 and 310 may be the same or different. In various non-limiting embodiments, one or both of the interliners 308 and 310 includes a third aluminum alloy comprising, in weight percentages based on total weight of the third aluminum alloy: 0.05 to 1.5 silicon; 0 to 2 manganese; 0 to 2 magnesium; 0 to 2 copper; 0 to 0.8 iron; 0 to 3 zinc; 0 to 0.5 zirconium; 0 to 1.0 chromium; 0 to 0.5 bismuth; 0 to 0.3 titanium; optionally, incidental elements; impurities; and aluminum.

[0045] In various non-limiting embodiments, a clad composite according to the present disclosure does not comprise the interliner layer 310, and the layer 206 may be in direct contact with the core layer 102. For example, referring to the non-limiting embodiment shown schematically in FIG. 4, clad composite 400 comprises the core layer 102, the brazing layer 204, the layer 206, and the interliner layer 308, but lacks the interliner layer 310. In various non-limiting embodiments, the core layer 102, the brazing layer 204, the layer 206, and the interliner layer 308 are bonded (e.g., roll bonded) together to form the clad composite 400.

[0046] In various non-limiting embodiments, a clad composite according to the present disclosure does not comprise the interliner layer 310 or the layer 206, and the core layer 102 is exposed on one side. Referring to the non-limiting embodiment shown schematically in FIG. 5, for example, clad composite 500 comprises the core layer 102, the brazing layer 204, and an interliner layer 308. In various non-limiting embodiments, the core layer 102, the brazing layer 204, and the interliner layer 308 are bonded (e.g., roll bonded) together to form the clad composite 500.

[0047] The thickness of each layer in the clad composite 200, clad composite 300, clad composite 400, and clad composite 500 can be configured based on the desired structural properties of an article e.g., a heat exchanger) that is to be produced from or that is to incorporate the respective clad composite, 200, 300, 400, or 500. For example, in various non-limiting embodiments, the core layer 102 can comprise a first thickness, ti, that can be in a range of 60% to 93% of a total thickness (i.e., ttotai) of the respective clad composite 200, 300, 400, or 500. In various non-limiting embodiments, the interliner layer 308, if present, and the interliner layer 310, if present, can comprise third thicknesses, respectively t3 and t3',and the total interliner layer thickness i can be in a range of 3% to 30% of a total thickness (ttotai) of the respective clad composite 200, 300, 400, or 500. In various non-limiting embodiments, the brazing layer 204 and layer 206 can comprise second thicknesses, respectively t2 and t2', and a sum of the two thickness can be in a range of 3% to 20% of the total thickness (ttotai) of the respective clad composite 200, 300, 400, or 500. In various nonlimiting embodiments, the first thickness, ti, is greater than each second thickness, t2 and t2', and also is greater than each third thickness, t3 and t3'. In certain non-limiting embodiments, the total thickness (ttotai) of the clad composite 200, 300, 400, or 500 is in a range of 100 pm to 5 mm, such as, for example, in a range of 200 pm to 1 mm.

[0048] In various embodiments, the clad composite 100, 200, 300, 400, or 500 can have a composition of layers suitable for at least one of controlled atmospheric brazing and vacuum brazing. For example, the clad composite 100, 200, 300, 400, or 500 can comprise layers having compositions so that the clad composite is suitable for controlled atmospheric brazing and / or vacuum brazing. In various non-limiting embodiments in which the clad composite 100, 200, 300, 400, or 500 may be subjected to a brazing process utilizing a flux, magnesium diffusion from the clad composite according to the present disclosure may be undesirable as it may interfere with the flux. In various non-limiting embodiments, a clad composite according to the present disclosure is configured to inhibit diffusion from the clad composite (e.g., inhibit diffusion of magnesium) such that flux can be used in the brazing process. In certain non-limiting embodiments, the clad composite 100, 200, 300, 400, or 500 according to the present disclosure may have a composition suitable for vacuum brazing (e.g., fluxless vacuum brazing). In various non-limiting embodiments in which the clad composite 100, 200, 300, 400, or 500 is subjected to flux-free brazing (e.g., brazing in an inert atmosphere with residual O2 in a CAB furnace, without the use of a flux), magnesium diffusion from the clad composite can be advantageous, for example, to dissolve an oxide layer formed on a brazing layer and / or facilitate wettability of the surface to be brazed.

[0049] In various non-limiting embodiments, an article such as, for example, a heat exchanger, can comprise a structural element comprising all or a portion of clad composite 100, 200, 300, 400, or 500 or another clad composite embodiment according to the present disclosure . The heat exchanger can have a galvanic corrosion resistance evaluated under ASTM G85 Annex A3 (2019) that is at least 20 days, such as, for example, at least 25 days, or at least 30 days. The heat exchanger can be, for example, an oil cooler, a radiator, acooling system (e.g., battery cooling system), a liquid cooled condenser, or a combination thereof. In various non-limiting embodiments, the article can comprise a tube shape.

[0050] FIG. 6 provides a block diagram of a non-limiting embodiment of a method according to the present disclosure for forming an article of manufacture such as, for example, a heat exchanger. The method embodiment comprises contacting a first part comprising a first material with a second part comprising all or a portion of a non-limiting embodiment of a clad composite according to the present disclosure. For example, a non-limiting embodiment of a method according to the present disclosure may comprise contacting a first part comprising a first material with a second part comprising all or a portion of clad composite 100, 200, 300, 400, 500, and / or a different embodiment of a clad composite according to the present disclosure (FIG. 6, step 602). In various non-limiting embodiments, the first part is brazed to the second part by a process comprising at least one of controlled atmospheric brazing and vacuum brazing (FIG. 6, step 604). In various non-limiting embodiments, the first material comprises aluminum or an aluminum alloy.

[0051] The following numbered clauses are directed to various non-limiting embodiments and aspects according to the present disclosure.

[0052] Clause 1. An aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2.0 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and a copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1, wherein Cueqis calculated by the following equation:CUeq=[Cu] - (1.9 • [Zn]) wherein [Cu] and [Zn], respectively, are the weight percentages of copper and of zinc in the aluminum alloy.

[0053] Clause 2. The aluminum alloy of clause 1, wherein the copper equivalent value of the aluminum alloy is in a range of 0.05 to 0.2.

[0054] Clause 3. The aluminum alloy of clause 1, wherein the copper equivalent value of the aluminum alloy is in a range of 0.12 to 0.18.

[0055] Clause 4. The aluminum alloy of any of clauses 1-3, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy, 0.2 to 0.4 zinc.

[0056] Clause 5. The aluminum alloy of any of clauses 1-4, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy, 0.4 to 1.0 copper.

[0057] Clause 6. The aluminum alloy of any of clauses 1-5, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy: 0.6 to 0.84 silicon; 1.1 to 1.4 manganese; 0.2 to 0.4 zinc; 0.4 to 1.0 copper; 0.4 to 0.6 iron; 0 to 0.05 magnesium; 0.1 to 0.2 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and the copper equivalent value of the aluminum alloy is in a range of 0.05 to 1.

[0058] Clause 7. The aluminum alloy of any of clauses 1-6, wherein the aluminum alloy comprises at least 20% scrap material.

[0059] Clause 8. A sheet product comprising the aluminum alloy of any of clauses 1-7.

[0060] Clause 9. An article of manufacture comprising a structural element made from elements comprising all or a portion of the sheet product of clause 8.

[0061] Clause 10. The article of manufacture of clause 9, wherein the article comprises a heat exchanger.

[0062] Clause 11. The article of manufacture of clause 10, wherein the heat exchanger comprises an oil cooler, a battery cooling system, a liquid cooled condenser, or a combination thereof.

[0063] Clause 12. A clad composite comprising: a core layer comprising a first aluminum alloy, wherein the first aluminum alloy is the aluminum alloy of any of clauses 1- 7; and a first layer disposed on the core layer, the first layer comprising a second aluminum alloy.

[0064] Clause 13. The clad composite of clause 12, wherein the first layer is an interliner layer comprising a 1XXX series aluminum alloy, a 3XXX series aluminum alloy, or a 7XXX series aluminum alloy.

[0065] Clause 14. The clad composite of clause 12, wherein the first layer is a brazing layer and the brazing layer comprises a 4XXX series aluminum alloy.

[0066] Clause 15. The clad composite of clause 12, wherein the first layer is a waterside liner layer, and wherein the second aluminum alloy comprises, in weight percentages based on a total weight of the second aluminum alloy: 0.5 to 12 zinc; 0.1 to 1.2 silicon; 0 to 1 iron; 0 to 0.3 copper; 0 to 1.5 manganese; 0 to 0.6 magnesium; 0 to 0.2 titanium; 0 to 0.2 zirconium; optionally, incidental elements; impurities; and aluminum.

[0067] Clause 16. The clad composite of any of clauses 12-15, wherein the clad composite comprises two layers, three layers, four layers, or five layers.

[0068] Clause 17. A method for forming an article of manufacture, the method comprising: contacting a first part comprising a first material with a second part comprising all or a portion of the clad composite of any of clauses 12-16; and brazing the first part to the second part by a process comprising at least one of controlled atmospheric brazing and vacuum brazing.

[0069] Clause 18. A method for manufacturing an aluminum alloy, the method comprising: melting a charge comprising at least 20% by weight scrap material from postconsumer brazing scrap, based on a total weight of the feed material, and a non-scrap feed material; and forming an ingot from the molten charge.

[0070] Clause 19. The method of clause 18, wherein the scrap material comprises at least 0.1 percent by weight zinc based on total weight of the scrap material.

[0071] Clause 20. The method of any of clauses 18-19, wherein the ingot comprises an aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy: 0.3 to 1.1 silicon; 0.3 to 2 manganese; 0.2 to 1.0 zinc; 0.4 to 2.0 copper; 0 to 0.7 iron; 0 to 0.8 magnesium; 0 to 0.25 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and a copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1, wherein Cueqis calculated by the following equation:CUeq=[Cu] - (1.9 • [Zn]) wherein [Cu] and [Zn], respectively, are the weight percentages of copper and of zinc in the aluminum alloy.

[0072] Clause 21. The method of clause 20, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy: 0.6 to 0.84 silicon; 1.1 to 1.4 manganese; 0.2 to 0.4 zinc; 0.4 to 1.0 copper; 0.4 to 0.6 iron; 0 to 0.05 magnesium; 0.1 to 0.2 titanium; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and the copper equivalent value of the aluminum alloy is in a range of 0.05 to 0.2.

[0073] In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term “about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0074] Also, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of “1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Also, all ranges recited herein are inclusive of the end points of the recited ranges. For example, a range of “1 to 10” includes the end points 1 and 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

[0075] The grammatical articles “a,” “an,” and “the,” as used herein, are intended to include “at least one” or “one or more,” unless otherwise indicated, even if “at least one” or “one or more” is expressly used in certain instances. Thus, the foregoing grammatical articles are used herein to refer to one or more than one (i.e., to “at least one”) of the particular identified elements. Further, the use of a singular noun includes the plural and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

[0076] One skilled in the art will recognize that the herein described articles and methods, and the discussion accompanying them, are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific examples / embodiments set forth and the accompanying discussions are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components, devices, operations / actions, and objects should not be taken to be limiting.While the present disclosure provides descriptions of various specific aspects for the purpose of illustrating various aspects of the present disclosure and / or its potential applications, it is understood that variations and modifications will occur to those skilled in the art.Accordingly, the invention or inventions described herein should be understood to be at least as broad as they are claimed and not as more narrowly defined by particular illustrative aspects provided herein.

Claims

CLAIMSWhat is claimed is:

1. An aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy:0.3 to 1.1 silicon;0.3 to 2.0 manganese;0.2 to 1.0 zinc;0.4 to 2.0 copper;0 to 0.7 iron;0 to 0.8 magnesium;0 to 0.25 titanium;0 to 0.3 chromium;0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and wherein a copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1, wherein Cueqis calculated by the following equation:CUeq=[Cu] - (1.9 • [Zn]) wherein [Cu] and [Zn], respectively, are the weight percentages of copper and of zinc in the aluminum alloy.

2. The aluminum alloy of claim 1, wherein the copper equivalent value of the aluminum alloy is in a range of 0.05 to 0.2.

3. The aluminum alloy of claim 1, wherein the copper equivalent value of the aluminum alloy is in a range of 0.12 to 0.18.

4. The aluminum alloy of claim 1, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy, 0.2 to 0.4 zinc.

5. The aluminum alloy of claim 1, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy, 0.4 to 1.0 copper.

6. The aluminum alloy of claim 1, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy:0.6 to 0.84 silicon;1.1 to 1.4 manganese;0.2 to 0.4 zinc;0.4 to 1.0 copper;0.4 to 0.6 iron;0 to 0.05 magnesium;0.1 to 0.2 titanium;0 to 0.3 chromium;0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; and wherein the copper equivalent value of the aluminum alloy is in a range of 0.05 to 1.

7. The aluminum alloy of claim 1, wherein the aluminum alloy comprises at least 20% scrap material.

8. A sheet product comprising the aluminum alloy of claim 1.

9. An article of manufacture comprising a structural element comprising all or a portion of the sheet product of claim 8.

10. The article of manufacture of claim 9, wherein the article comprises a heat exchanger.

11. The article of manufacture of claim 10, wherein the heat exchanger comprises an oil cooler, a battery cooling system, a liquid cooled condenser, or a combination thereof.

12. A clad composite comprising: a core layer comprising a first aluminum alloy, wherein the first aluminum alloy is the aluminum alloy of claim 1; and a first layer disposed on the core layer, the first layer comprising a second aluminum alloy.

13. The clad composite of claim 12, wherein the first layer is an interliner layer comprising a 1XXX series aluminum alloy, a 3XXX series aluminum alloy, or a 7XXX series aluminum alloy.

14. The clad composite of claim 12, wherein the first layer is a brazing layer comprising a 4XXX series aluminum alloy.

15. The clad composite of claim 12, wherein the first layer is a waterside liner layer, and wherein the second aluminum alloy comprises, in weight percentages based on a total weight of the second aluminum alloy:0.5 to 12 zinc;0.1 to 1.2 silicon;0 to 1 iron;0 to 0.3 copper;0 to 1.5 manganese;0 to 0.6 magnesium;0 to 0.2 titanium;0 to 0.2 zirconium; optionally, incidental elements; impurities; and aluminum.

16. The clad composite of claim 12, wherein the clad composite comprises two layers, three layers, four layers, or five layers.

17. A method for forming an article of manufacture, the method comprising: contacting a first part comprising a first material with a second part comprising all or a portion of the clad composite of claim 12; and brazing the first part to the second part by a process comprising at least one of controlled atmospheric brazing and vacuum brazing.

18. A method for manufacturing an aluminum alloy, the method comprising:melting a charge comprising at least 20% by weight scrap material from postconsumer brazing scrap, based on a total weight of the first feed material, and non-scrap feed material; and forming an ingot from the molten charge.

19. The method of claim 18, wherein the scrap material comprises at least 0.1 percent by weight zinc based on total weight of the scrap material.

20. The method of claim 18, wherein the ingot comprises an aluminum alloy comprising, in weight percentages based on total weight of the aluminum alloy:0.3 to 1.1 silicon;0.3 to 2 manganese;0.2 to 1.0 zinc;0.4 to 2.0 copper;0 to 0.7 iron;0 to 0.8 magnesium;0 to 0.25 titanium;0 to 0.3 chromium;0 to 0.25 zirconium; optionally, incidental elements; impurities; and wherein a copper equivalent value (Cueq) of the aluminum alloy is in a range of 0 to 1, wherein Cueqis calculated by the following equation:CUeq=[Cu] - (1.9 • [Zn]) wherein [Cu] and [Zn], respectively, are the weight percentages of copper and of zinc in the aluminum alloy..

21. The method of claim 20, wherein the aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy:0.6 to 0.84 silicon;1.1 to 1.4 manganese;0.2 to 0.4 zinc;0.4 to 1.0 copper;0.4 to 0.6 iron;0 to 0.05 magnesium;0.1 to 0.2 titanium;0 to 0.3 chromium;0 to 0.25 zirconium; optionally, incidental elements; impurities; and aluminum; wherein the copper equivalent value of the aluminum alloy is in a range of 0.2.

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