High recycle content aluminum alloys for automotive applications

Abstract

Aluminum alloys can be fabricated with a high recycled content material, including mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material) and end of live scrap, and processed to provide high strength and formability. Aluminum alloys are provided that are well suited for use as structural automotive parts, even at high loading of recycled materials.

Description

Attorney Docket No. 108050-1527047HIGH RECYCLE CONTENT ALUMINUM ALLOYS FOR AUTOMOTIVE APPLICATIONSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 702,933, filed October 3, 2024, and U.S. Provisional Patent Application No. 63 / 716,322, filed November 5, 2024, which are hereby incorporated by reference in their entireties for all intents and purposes.FIELD

[0002] The disclosure is directed to aluminum alloys that may be fabricated with a high recycled content. In particular, the present disclosure generally provides recycle friendly series aluminum alloys that utilize low amounts of prime aluminum (e.g., less than 20%, in aspects) while providing excellent strength and formability. The disclosure also provides various end uses of such products, such as in automotive, transportation, electronics, industrial, aerospace, and other applications, including structural automotive applications.BACKGROUND

[0003] High-strength aluminum alloys are used in many different applications, particularly in applications where strength and durability are required. For example, 6xxx series aluminum alloys have been widely used in automobile applications due to their superior combination of properties including strength-to-weight ratio, formability, weldability, and general corrosion resistance. 6xxx series aluminum alloys are commonly used for automotive structural and closure panel applications in place of steel. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials reduces the weight of the vehicle and allows for substantial improvements in its fuel economy. Existing 6xxx series auto sheet aluminum alloys often fail to incorporate high levels of non-6xxx aluminum scraps, such as those aluminum alloy scraps including large amounts of silicon, manganese, and iron, as such alloying elements may compromise the properties of the alloy.

[0004] Most high strength 6xxx series aluminum alloys currently available on the market for skin and structural automotive applications (e.g., AA6014, AA6016, AA6451, AA6111 and AA6011) include relatively low amounts of Si (e.g., less than 1.5 wt. %) and have limited recyclability. Additionally, many sources of aluminum alloy scrap, such as Twitch, containAttorney Docket No. 108050-1527047 significantly higher amounts of Si (e.g., 4 to 10 wt. % Si) than conventional 6xxx series aluminum alloys used in skin and structural applications, limiting the use of aluminum scrap in automotive applications and hindering its recyclability.

[0005] Recently, brazing materials have become an aluminum alloy of interest, as the materials are difficult to recycle, but plentiful and relatively inexpensive in the scrap market. There is therefore a desire to recycle brazing materials. Brazing materials usually contain mixtures of 3xxx or 6xxx and 4xxx series aluminum alloys, resulting in high levels of silicon, iron, manganese, copper, and magnesium, amongst others in the recycled material. Thus, brazing materials have so far proven difficult to recycle.

[0006] In order to improve circularity and recyclability in the automotive industry, there is a need for new aluminum alloys that can improve the recycled content in automotive applications. In addition, there is a need to provide materials suitable for use in automotive applications, such as having good strength and formability, that can incorporate high levels of recycled material. It would also be beneficial to provide an aluminum alloy for automotive applications that is similar in alloy content to other automotive aluminum alloys, such that recyclability of automobile parts may be improved.SUMMARY

[0007] 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.

[0008] The present technology is generally directed to aluminum alloys that include 0.8 wt. % to 4.6 wt. % silicon, 0.0 wt. % to 0.9 wt. % iron, 0.05 wt. % to 1.2 wt. % copper, 0.4 wt. % to 1.4 wt. % manganese, 0.05 wt.% to 0.9 wt.% magnesium, up to 0.4 wt. % chromium, up to 1.00 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum. Alloys exhibit a uniform elongation of greater than or about 15% in a T4 temper or an O temper or an under-solutionized condition.

[0009] The present technology is generally directed to aluminum alloys that include 0.8 wt. % to 2.7 wt. % silicon, 0.0 wt. % to 0.9 wt. % iron, 0.05 wt. % to 0.9 wt. % copper, 0.4 wt.Attorney Docket No. 108050-1527047% to 1.4 wt. % manganese, 0.05 wt.% to 0.7 wt.% magnesium, up to 0.4 wt. % chromium, up to 0.4 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum. Alloys exhibit a uniform elongation of greater than or about 15% in a T4 temper or an O temper or an under-solutionized condition.

[0010] In embodiments, the aluminum alloy includes at least 50 wt. % recycled content, and at least 50 wt. % of the recycled content is a mixed cladded alloy recycled material. Moreover, in embodiments, the recycled content includes 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 further embodiments, the aluminum alloy includes at least 70 wt. % recycled material, and at least 55 wt. % of the recycled material is a mixed cladded alloy recycled material. In embodiments, alloys include 0.9 wt. % to 2.6 wt. % silicon, 0.0 wt. % to 0.8 wt. % iron, 0.07 wt. % to 0.8 wt. % copper, 0.5 wt. % to 1.3 wt. % manganese, 0.07 wt.% to 0.6 wt.% magnesium, up to 0.3 wt. % chromium, up to 0.3 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum. In yet more embodiments, alloys include 1.0 wt. % to 2.5 wt. % silicon, 0.01 wt. % to 0.7 wt. % iron, 0.1 wt. % to 0.7 wt. % copper, 0.6 wt. % to 1.2 wt. % manganese, 0.1 wt.% to 0.5 wt.% magnesium, up to 0.2 wt. % chromium, up to 0.2 wt. % zinc, up to 0.2 wt. % titanium, up to 0.2 wt. % of impurities, and aluminum. Additionally or alternatively, in embodiments, the aluminum alloy exhibits a yield strength of greater than or about 120 MPa in a T4 temper. Embodiments include where the aluminum alloy exhibits a yield strength of less than or about 80 MPa in an O temper or an under-solutionized condition. In more embodiments, the aluminum alloy exhibits a yield strength of greater than or about 220 MPa in a T8 temper. Furthermore, in embodiments, the aluminum alloy exhibits a yield strength of greater than or about 250 MPa in a T6 temper.

[0011] The present technology is also generally directed to products fabricated with the aluminum alloy of any one or more of the above embodiments, where the product comprises a structural automotive part.

[0012] The present technology is further generally directed to methods of producing an aluminum alloy. Methods include casting an aluminum alloy to form a cast product, where the aluminum alloy includes 0.8 wt. % to 2.7 wt. % silicon, 0.0 wt. % to 0.9 wt. % iron, 0.05 wt. % to 0.9 wt. % copper, 0.4 wt. % to 1.4 wt. % manganese, 0.05 wt.% to 0.7 wt.% magnesium, up to 0.4 wt. % chromium, up to 0.4 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum. Methods include optionally homogenizing and / or pre-heating theAttorney Docket No. 108050-1527047 cast product, hot rolling the optionally homogenized and / or pre-heated product to produce a hot rolled product, and optionally cold rolling the hot rolled product and optionally interannealing to produce a cold rolled product. Methods include solution heat treating or annealing the final gauge rolled product, optionally pre-ageing the solution heat treated product, and optionally artificial aging of the solution heat treated product or the pre-aged product.

[0013] In embodiments, methods include aging the final gauge rolled product to a T temper. Furthermore, in embodiments, the T temper is a T4 temper, a T6 temper, or a T8 temper. In more embodiments, methods include treating the product to an O temper or an under-solutionized condition. Embodiments include where the cast product is cast from an aluminum alloy having one or more of 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. Additionally or alternatively, in embodiments, the cast product is cast from an aluminum alloy comprising at least 70 wt. % recycled material, and wherein at least 55 wt. % of the recycled material is a mixed cladded alloy recycled material. In embodiments, the cast product is cast from an aluminum alloy comprising less than 20 wt. % prime aluminum.

[0014] Ther present technology is also generally directed to products fabricated with the aluminum alloy of, or formed according to, any one or more of the above embodiments. In embodiments, the product includes a structural automotive part.

[0015] Described herein are aluminum alloys that include 1.70 - 4.60 wt. % Si, 0.10 - 0.70 wt. % Fe, up to 0.60 wt. % Mn, up to 0.90 wt. % Mg, up to 1.20 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al, wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.50 wt. % Si, or combinations thereof, and wherein the aluminum alloy is produced from less than 20 wt. % prime aluminum. In some cases, the aluminum alloys include 1.70 - 4.50 wt. % Si, 0.40 - 0.60 wt. % Fe, up to 0.60 wt. % Mn, 0.60 - 0.90 wt. % Mg, 0.75 - 1.20 wt. % Cu, up to 0.30 wt. % Cr, 0.40 - 0.60 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 1.70 - 4.50 wt. % Si, 0.40 - 0.60 wt. % Fe, up to 0.60 wt. % Mn, up to 0.90 wt. % Mg, up to 1.20 wt. % Cu, up to 0.30 wt. % Cr, up to 0.60 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 2.50 - 4.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities,Attorney Docket No. 108050-1527047 and remainder Al. In some cases, the aluminum alloys include 2.50 - 4.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, up to 0.45 wt. % Mg, up to 0.45 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 1.70 - 2.50 wt. % Si, 0.40 - 0.50 wt. % Fe, up to 0.30 wt. % Mn, up to 0.60 wt. % Mg, up to 0.75 wt. % Cu, up to 0.30 wt. % Cr, up to 0.40 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 1.70 - 2.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 1.70 - 2.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, 0.45 - 0.60 wt. % Mg, 0.40 - 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 1.70 - 2.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.20 wt. % Mn, up to 0.45 wt. % Mg, up to 0.45 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 4.00 - 4.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.40 wt. % Mn, up to 0.60 wt. % Mg, 0.30 - 0.40 wt. % Cu, up to 0.30 wt. % Cr, up to 0.30 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al. In some cases, the aluminum alloys include 1.70 - 4.50 wt. % Si, 0.10 - 0.50 wt. % Fe, up to 0.50 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0016] In some cases, the aluminum alloy can have a ratio of a-phase and P-phase second phase particles (a-phase / P-phase) from 0.6 to 1.5. In some cases, the ratio of a-phase / P-phase is from 0.7 to 1.1. In some examples, the aluminum alloy can have a yield strength (RP0.2) from 80 MPa to 180 MPa when in a T4 temper, and a tensile strength (Rm) of the aluminum alloy is from 200 MPa to 350 MPa when in a T4 temper. In some cases, the aluminum alloy can have a yield strength (RP0.2) from 230 MPa to 320 MPa when in a T6 temper, and a tensile strength (Rm) from 310 MPa to 370 MPa when in a T6 temper. In some cases, the aluminum alloy can have a yield strength (Rp 0.2) from 230 MPa to 310 MPa when in a T8x temper, and a tensile strength (Rm) of the aluminum alloy is from 290 MPa to 360 MPa when in a T8x temper. In some cases, the aluminum alloy can have a bending beta angle of 50° to 85° as measured according to VDA238-100 (2023) when in a T4 temper. In some cases, the aluminum alloy can have an intergranular corrosion depth from 290 - 370 pm when in a T6 temper as measured according to ISO 11846B. In some cases, the aluminum alloy can have an intergranular corrosion depth of less than 330 pm when in a T6 temper as measured accordingAttorney Docket No. 108050-1527047 to ISO 11846B. In some cases, the aluminum alloy can have an intergranular corrosion depth of 230 - 270 pm when in a T8x temper as measured according to ISO 11846B. In some cases, the aluminum alloy is a 6xxx series aluminum alloy. In some cases, the aluminum alloy is used to produce automotive parts for skin or structural applications.

[0017] Also described herein is a method of producing an aluminum alloy including casting an aluminum alloy to form a cast product, wherein the aluminum alloy includes 1.70 - 4.60 wt. % Si, 0.10 - 0.70 wt. % Fe, up to 0.40 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al, wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.5 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from up to 20 wt. % prime aluminum; homogenizing the cast product; hot rolling the cast product to produce a hot rolled product; cold rolling the rolled product to produce a final gauge rolled product; and solution heat treating the final gauge rolled product. In some cases, the method further includes aging the final gauge rolled product to a T temper, including, but not limited to, a T4 temper, a T6 temper, T8x, or a T82 temper. In some cases, the method further includes pre-straining the final gauge rolled product. In some cases, the method includes a ratio of end-of-life scrap to run-around scrap in the aluminum alloy of 1 : 1. In some cases, the final gauge rolled product is a sheet. In some cases, the method further includes joining the sheet to one or more additional alloy products by remote laser welding without filler wire. In some cases, at least one of the one or more additional alloy products is an aluminum alloy sheet comprising the composition as described herein.

[0018] Also provided herein is a method for joining aluminum alloy products, the method including: providing a first aluminum alloy product comprising 1.70 - 4.60 wt. % Si, 0.10 - 0.70 wt. % Fe, up to 0.40 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al, wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.50 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from less than 20 wt. % prime aluminum; providing a second aluminum alloy product; joining the first aluminum alloy product to the second aluminum alloy product by remote laser welding without filler wire. In some cases, the first aluminum alloy product is monolithic. In someAttorney Docket No. 108050-1527047 cases, the second aluminum alloy product is monolithic. In some cases, the first aluminum alloy product is a rolled aluminum alloy sheet.

[0019] 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

[0020] FIG. 1 provides scanning election microscopy images of the microstructure of example alloys described herein.

[0021] FIG. 2 provides a graph of the yield strength (RP0.2, MPa) (x-axis) and the total elongation (Ag) (y-axis) of example alloys in a T4 temper.

[0022] FIG. 3 provides a graph of the DC bending (P, °) (x-axis) and the F-factor (15 % pre-strain) (y-axis) of example alloys in a T4 temper.

[0023] FIGS. 4A-D provide graphs of the average nl0-15 values and average r8-12 values of example alloys in the longitudinal, diagonal, and transverse directions.

[0024] FIG. 5 provides a graph of the yield strength (RP0.2, MPa)(2 % pre-strain, 185° C for 20 minutes) (x-axis) of example alloys in a T8x temper and the total elongation (Ag) of example alloys in a T4 temper.

[0025] FIG. 6 provides a graph of the yield strength (RP0.2, MPa) (y-axis) as a function of the Mg content (wt. %) (x-axis) of example alloys in a T4 temper.

[0026] FIG. 7 provides a graph of the Mg content (wt. %) (x-axis) and the F factor (15 % pre-strain)(y-axis) of example alloys in a T4 temper.

[0027] FIG. 8 provides a graph of the yield strength (RP0.2, MPa)(x-axis) and the total elongation (Ag)(y-axis) of example alloys in a T4 temper.

[0028] FIG. 9 provides a graph of the yield strength (RP0.2, MPa) (x-axis) and the DC bending angle (P, °) (y-axis) of example alloys in a T4 temper.

[0029] FIG. 10A provides graphs of the yield strength (RP0.2, MPa) (x-axis) and the total elongation (Ag) of example alloys in a T6 and T8x temper, respectively. FIG. 10B provides graphs of the tensile strength (Rm, MPa) (x-axis) and the total elongation (Ag) of example alloys in a T6 and T8x temper, respectively.

[0030] FIG. 11 provides a graph of the yield strength (RP0.2, MPa) (x-axis) and the DC bending angle (P, °) (y-axis) of example alloys in a T6 temper (180° C, 10 hours) and T8x temper (2% pre-strain, 185° C for 20 minutes), respectively.Attorney Docket No. 108050-1527047

[0031] FIG 12 provides scanning election microscopy images of the microstructure of example alloys described herein in Example 3.DETAILED DESCRIPTION OF THE INVENTION

[0032] Described herein are aluminum alloys that contain up to 4.60 wt.% silicon, that may be produced from a high proportion of recycled aluminum alloy scrap, which exhibit a combination of high strength and formability. Namely, the present technology has surprisingly found that by carefully producing an aluminum alloy according to the methods discussed herein, a high proportion of recycled aluminum alloy scrap may be used in the aluminum alloy, including a high proportion of recycled aluminum alloy scraps from mixed cladded alloy recycled materials, such as recycled brazing aluminum alloys. The processes and aluminum alloys discussed herein allow for a strong and formable aluminum alloy to be provided that may be compositionally similar to, or be, a 4xxx series or 6xxx series aluminum alloy, that also exhibits alloy and alloy property similarity to 6xxx series aluminum alloys and / or brazing sheets, improving the recyclability of mixed automotive parts. The aluminum alloys described herein have a carefully controlled composition that achieves similar or better strength and formability properties than conventional 4xxx or 6xxx series aluminum alloys despite including up to 4.60 wt. % Si.

[0033] In embodiments, the present technology may utilize one or more solution heat treatment operations. The solution heat treatment operation, in conjunction with the presence of alloying elements such as magnesium, copper, and silicon, may allow for the formation of an aluminum alloy having excellent strength due at least in part to precipitation strengthening (e.g. Mg2Si, P" precipitates) by aging after solution heat treatment. Furthermore, the presence of alloying elements such as manganese, copper, zinc, and iron in the aluminum alloy may compensate, alone or in combination with the solution heat treatment, for the high silicon content, to provide a refined grain structure and weak texture after solution heat treatment of the aluminum alloys discussed herein. Therefore, the present technology may provide a method and alloy for utilizing brazing material scraps, while also improving the recyclability of automotive parts.

[0034] Beneficially, the aluminum alloy compositions described herein provide a combination of good mechanical properties, low prime content, and can incorporate high Si content recycled aluminum alloy to replace existing high strength 6xxx series aluminum alloys for skin and structural applications. The aluminum alloys described herein provide a cleaner,Attorney Docket No. 108050-1527047 unified aluminum alloy that improves recyclability and circularity. The aluminum alloys described herein allows mixing of high strength 6xxx series aluminum alloy with other types of aluminum alloy scrap, including brazing scrap, without the need for segregation or sorting, which is a major hurdle for recycling. Additionally, the aluminum alloys described herein are finely tuned in order to accept high recycling content (e.g., less than 20 wt. % prime aluminum), and high silicon content. The aluminum alloys described herein provides a replacement for many high strength 6xxx series aluminum alloys including low amounts of Si and are suitable for both skin and structural automotive applications, thereby promoting recyclability and circularity. For instance, the aluminum alloys described herein exhibit comparable strength, elongation, and bendability properties as 6xxx series aluminum alloys including lower amounts of Si. The aluminum alloys described herein can be produced from less than 20 wt. % prime aluminum, which substantially reduces the cost and environmental impact of producing the aluminum alloy. Prime aluminum is typically the most energy and cost-intensive component of producing aluminum alloys. Beneficially, the aluminum alloys described herein can exhibit the same properties (e.g., mechanical, corrosion, and / or forming properties) as 6xxx series aluminum alloys including lower amounts of Si despite being produced from less than 20 wt. % prime aluminum. Additionally, the aluminum alloys described herein allows for easier aluminum alloy scrap management and provides a low carbon footprint for end users.

[0035] 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, brazing materials, and the like) and / or the production thereof. Herein, the term “mixed cladded alloy, pre-consumer recycled 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.

[0036] While cladded aluminum alloy products can be made of many different series of aluminum alloys, 4xxx series aluminum alloys are typically used in the cladding layer, and 3xxx or 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,Attorney Docket No. 108050-1527047 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).Definitions and Descriptions

[0037] 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.

[0038] 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.

[0039] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0040] 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.

[0041] 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.

[0042] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm (e.g., less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm). For example, a sheet may have a thickness of about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5, about 0.6 mm about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6Attorney Docket No. 108050-1527047 mm about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, or about 4 mm.

[0043] As used herein, formability refers to the ability of a material to undergo deformation into a desired shape without fracturing, tearing-off, necking, earing, or shaping errors such as wrinkling, spring-back, or galling occurring. In engineering, formability may be classified according to deformation modes. Examples of deformation modes include drawing, stretching, bending, and stretch-flanging.

[0044] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0045] 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 certain examples of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of the impurities.

[0046] 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 departingAttorney Docket No. 108050-1527047 from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

[0047] 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.

[0048] 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.

[0049] 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%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, orAttorney Docket No. 108050-1527047 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.

[0050] 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. %).Aluminum Alloy Compositions Fabricated using Recycled Material

[0051] Described below are aluminum alloys that can be fabricated using a high recycled content, including mixed cladded alloy recycled materials (e.g., a mixed cladded alloy, preconsumer recycled material), end-of-life scrap, run-around scrap, and / or closed-loop scrap, in embodiments. The aluminum alloys exhibit high strength and formability, despite having a high content of Si. The properties of the aluminum alloys are achieved due to the compositions and / or methods of making the alloys, as discussed above.

[0052] The aluminum alloys can have the following elemental composition as provided in Table 1 :Table 1Attorney Docket No. 108050-1527047

[0053] The aluminum alloys can also have the following elemental composition as provided in Table 2:Table 2

[0054] In other examples, the aluminum alloys can have the following elemental composition as provided in Table 3.Table 3Attorney Docket No. 108050-1527047

[0055] In other examples, the aluminum alloys can have the following elemental composition as provided in Table 4.Table 4

[0056] Additionally or alternatively, in other examples, the aluminum alloys can have the following elemental composition as provided in Table 5.Table 5

[0057] In some examples, an aluminum alloy as described herein can have the following elemental composition as provided in Table 6.Attorney Docket No. 108050-1527047Table 6

[0058] In some examples, an aluminum alloy as described herein can have the following elemental composition as provided in Table 7.Table 7

[0059] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 8.Attorney Docket No. 108050-1527047Table 8

[0060] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 9.Table 9

[0061] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 10.Attorney Docket No. 108050-1527047Table 10

[0062] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 11.Table 11

[0063] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 12.Attorney Docket No. 108050-1527047Table 12

[0064] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 13.Table 13

[0065] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 14.Attorney Docket No. 108050-1527047Table 14

[0066] In some examples, an aluminum alloy as described herein can have the following elemental composition as provided in Table 15.Table 15

[0067] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 1-15, 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.Attorney Docket No. 108050-1527047Silicon (Si)

[0068] In embodiments, the aluminum alloys described herein are suitable for remote laser welding applications, without a filler wire. For example, an aluminum alloy product described herein can be joined to another product by remote laser welding without filler wire and has excellent mechanical properties and does not form cracks. In some embodiments, an aluminum alloy product described herein can be a monolithic product (e.g., a single, non-composite alloy) that is joined to another aluminum alloy product by remote laser welding without filler wire.

[0069] In some examples, the aluminum alloy described herein includes Si in an amount of from 0.80 % to 4.60 % (e.g., from 0.90 % to 4.50 %, from 1.00 % to 4.00 %, from 1.10% to 4.50 %), based on the total weight of the alloy. For example, the alloy can include 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %,0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %.1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %. 1.10 %, 1.11 %, 1.12 %. 1.13 %, 1.14 %,1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %. 1.21 %, 1.22 %, 1.23 %. 1.24 %, 1.25 %,1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %. 1.32 %, 1.33 %, 1.34 %. 1.35 %, 1.36 %,1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %. 1.43 %, 1.44 %, 1.45 %. 1.46 %, 1.47 %,1.48 %, 1.49 %, 1.50 %. 1.51 %, 1.52 %, 1.53 %, 1.54 %, 1.55 %, 1.56 %, 1.57 %, 1.58 %,1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %, 1.66 %, 1.67 %, 1.68 %, 1.69 %,1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %, 1.77 %, 1.78 %, 1.79 %, 1.80 %,1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %, 1.88 %, 1.89 %, 1.90 %, 1.91 %,1.92 %, 1.93 %, 1.94 %. 1.95 % 1.96 %, 1.97 %, 1.98 %, 1.99 %, 2.00 %, 2.01 %, 2.02 %.2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %, 2.10 %, 2.11 %, 2.12 %, 2.13 %,2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %, 2.21 %, 2.22 %, 2.23 %, 2.24 %,2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %, 2.32 %, 2.33 %, 2.34 %, 2.35 %,2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %, 2.43 %, 2.44 %, 2.45 %, 2.46 %,2.47 %, 2.48 %, 2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %, 2.54 %, 2.55 %, 2.56 %, 2.57 %,2.58 %, 2.59 %, 2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %, 2.65 %, 2.66 %, 2.67 %, 2.68 %,2.69 %, 2.70 %, 2.71 %, 2.72 %, 2.73 %, 2.74 %, 2.75 %, 2.76 %, 2.78 %, 2.79 %, 2.80 %,2.81 %, 2.82 %, 2.83 %, 2.84 %, 2.85 %, 2.86 %, 2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %,2.92 %, 2.93 %, 2.94 %, 2.95 %, 2.96 %, 2.97 %, 2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %,3.03 %, 3.04 %, 3.05 %, 3.06 %, 3.07 %, 3.08 %, 3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %,3.14 %, 3.15 %, 3.16 %, 3.17 %, 3.18 %, 3.19 %, 3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %,3.25 %, 3.26 %, 3.27 %, 3.28 %, 3.29 %, 3.30 %, 3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %,Attorney Docket No. 108050-15270473.36 %, 3.37 %, 3.38 %, 3.39 %, 3.40 %, 3.41 %, 3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %,3.47 %, 3.48 %, 3.49 %, 3.50 %, 3.51 %, 3.52 %, 3.53 %, 3.54 %, 3.55 %, 3.56 %, 3.57 %,3.58 %, 3.59 %, 3.60 %, 3.61 %, 3.62 %, 3.63 %, 3.64 %, 3.65 %, 3.66 %, 3.67 %, 3.68 %,3.69 %, 3.70 %, 3.71 %, 3.72 %, 3.73 %, 3.74 %, 3.75 %, 3.76 %, 3.78 %, 3.79 %, 3.80 %,3.81 %, 3.82 %, 3.83 %, 3.84 %, 3.85 %, 3.86 %, 3.87 %, 3.88 %, 3.89 %, 3.90 %, 3.91 %,3.92 %, 3.93 %, 3.94 %, 3.95 %, 3.96 %, 3.97 %, 3.98 %, 3.99 %, 4.00 %, 4.01 %, 4.02 %,4.03 %, 4.04 %, 4.05 %, 4.06 %, 4.07 %, 4.08 %, 4.09 %, 4.10 %, 4.11 %, 4.12 %, 4.13 %,4.14 %, 4.15 %, 4.16 %, 4.17 %, 4.18 %, 4.19 %, 4.20 %, 4.21 %, 4.22 %, 4.23 %, 4.24 %,4.25 %, 4.26 %, 4.27 %, 4.28 %, 4.29 %, 4.30 %, 4.31 %, 4.32 %, 4.33 %, 4.34 %, 4.35 %,4.36 %, 4.37 %, 4.38 %, 4.39 %, 4.40 %, 4.41 %, 4.42 %, 4.43 %, 4.44 %, 4.45 %, 4.46 %,4.47 %, 4.48 %, 4.49 %, 4.50 %, 4.51 %, 4.52 %, 4.53 %, 4.54 %, 4.55 %, 4.56 %, 4.57 %,4.58 %, 4.59 %, or 4.60 % Si, or any ranges or values therebetween. All expressed in wt. %.

[0070] The aluminum alloy described herein includes a balance of alloying elements to exhibit the same strength and formability as lower Si-content 6xxx series aluminum alloys or 4xxx aluminum alloys. This allows the aluminum alloys described herein to accommodate larger amounts of high Si content recycled aluminum alloy scrap from different sources (e.g., mixed aluminum alloy scrap) and utilize less prime aluminum. In order to reach the same level of strength and formability as 6xxx and / or 4xxx series aluminum alloys having lower amounts of silicon, alloying elements such as Fe, Mg, Cu and / pr Zn are carefully tailored, as described below. In some embodiments, the free Si in the matrix is from 1.50 wt. % to wt. 4.00 % (e.g., from 1.50 % to 2.50 %, or from 1.50 % to 3.50 %).Iron (Fe)

[0071] In certain examples, the disclosed alloy includes iron (Fe) in an amount from about 0.0 % to about 0.9 % (e.g., from 0.0 % to 0.8 %, from 0.0 % to 0.7 %, from 0.01 % to 0.7 %, from 0.10 % to 0.60 %, from 0.10 % to 0.45 %, from 0.15 % to 0.40 %, from 0.20 % to 0.35 %, from 0.25 % to 0.35 %, from 0.30 % to 0.35 %, from 0.40 % to 0.50 %, from 0.30 % to 0.60 %, or from 0.15 % to 0.40 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %,0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %,0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %,0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %,0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %,Attorney Docket No. 108050-15270470.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, or 0.90 % Fe. All expressed in wt. % based on the total weight of the aluminum alloy. In some cases, the disclosed alloy does not include Fe (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0072] In embodiments, the aluminum alloy includes second phase particles including, but not limited to, a-phase, Si, and 7t-Fe second phase particles. The inventors unexpectedly found that there is a direct relationship between the bending of the aluminum alloy (both the F-factor and DC P bending angle) and the fraction of second phase particles in the matrix, where a- phase and 7t-Fe second phase particles were found to have a more pronounced effect on bending than Si particles. For example, the F-factor can be expressed by the following equation, where the second phase particles are expressed in atomic percent (at. %):F-factor (15 % pre-strain) = 0.57 a-phase (at. %) + 0.15 Si (at. %) + 0.427t-Fe (at. %).

[0073] Additionally, the DC P bending angle can be expressed by the following equation:P-bending angle (°) = 33.6 + 24.6 a-phase (at. %) + 3.98 Si (at. %) + 16.3 7t-Fe (at. %).

[0074] Thus, in embodiments, the aluminum alloy described herein can tolerate a higher Si content while maintaining formability by carefully controlling the Fe content, thereby controlling Fe-based interm etallics. In some embodiments, the ratio of a-phase and P-phase second phase particles (a-phase / P-phase) is 0.6 to 1.5 (e.g., 0.7 to 1.1). For example, the ratio of a-phase and P-phase second phase particles can be 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5. However, as discussed above, it should be clear that, in embodiments, the alloy composition or the method of forming the aluminum alloy product may also allow for excellent properties in the high silicon aluminum alloy alone or in combination with the Fe levels discussed herein.Copper (Cu)

[0075] In certain examples, the disclosed alloy includes copper (Cu) in an amount up to 1.20 % (e.g., up to 1.10 %, up to 1.00 %, up to 0.75 %, up to 0.50 %, up to 0.45 %, up to 0.30 %, from 0.05 % to about 0.9 % from 0.07 % to 0.8 %, from 0.1 % to 0.7 %, or from 0.70 % to 1.20 %, from 0.30 % to 0.50 %, from 0.30 % to 0.40 %, from 0.40 % to 0.50 %, or from 0.35 % to 0.45 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %,0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %,0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 %, 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 %,Attorney Docket No. 108050-15270470.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %,0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %,0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %,0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 % 0.90%, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %,1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, or 1.20 % Cu. All expressed in wt. % based on the total weight of the aluminum alloy.Manganese (Mn)

[0076] In certain examples, the alloy can include manganese (Mn) in an amount from about up to 1.4 % (e.g., from 0.05 % to 1.4 % from 0.10 % to 1.3 %, from 0.20 % to 1.2 %, or from 0.10 % to 0.60 %, from 0.20 % to 0.50 %, from 0.30 % to 0.40 %, from 0.10 % to 0.50 %, from0.20 % to 0.40 %, from 0.10 % to 0.30 %, from 0.20 % to 0.30 %, from 0.20 % to 0.25 %, up to 0.40, or up to 0.20) based on the total weight of the alloy. For example, the alloy can include0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %,0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %,0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %,0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %,0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %,0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %,0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %,0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %,0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %,1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %,1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %, 1.39 %, or 1.40 % Mn. All expressed in wt. % based on the total weight of the aluminum alloy.Magnesium (Mg)

[0077] In certain examples, the disclosed alloy includes magnesium (Mg) in an amount up to 0.90 %, (e.g., up to 0.80 %, up to 0.60 %, up to 0.45 %, or from 0.05 % to 0.7 %, from 0.07 % to 0.6 %, from 0.1 % to 0.5 % from 0.45 % to 0.60 %, or from 0.60 % to 0.90 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04Attorney Docket No. 108050-1527047%, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %,0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %,0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, or 0.90 % % Mg. All expressed in wt. % based on the total weight of the aluminum alloy.

[0078] The Mg content may affect both the yield strength and the F-factor (R / t ratio) of the aluminum alloy. In some embodiments, the Mg / Si ratio is from 0.05 to 0.3 (e.g., 0.10 to 0.15, or from 0.10 to 0.25). In some embodiments, the Mg2Si phase particles are from 0.4 to 1.0 % (e.g., 0.5 to 0.8).Chromium (Cr)

[0079] In certain aspects, the alloy includes chromium (Cr) in an amount of up about 0.4 % (e.g., from 0 % to 0.3 %, from 0.0 % to 0.2 %, from 0.01 % to 0.2 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.40 % 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.Zinc (Zn)

[0080] In certain examples, the disclosed alloy includes zinc (Zn) in an amount of up to 1.00 % (e.g., up to 0.75 %, up to 0.60 %, up to 0.40 %, up to 0.30 %, up to 0.20 %, up to 0.10 %, up to 0.05, from 0 % to 0.3 %, from 0.0 % to 0.2 %, from 0.01 % to 0.2 %, or from 0.40 % to 0.60 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %,0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %,0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %,0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %,0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %,0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %,Attorney Docket No. 108050-15270470.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.78 %, 0.79 %,0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %,0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, or 1.00 % Zn. In some cases, the disclosed alloy does not include Zn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.Titanium (Ti)

[0081] In certain aspects, the alloy includes titanium (Ti) in an amount of up about 0.4 % (e.g., from 0 % to 0.3 %, from 0.0 % to 0.2 %, from 0.01 % to 0.2 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.40 % 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.

[0082] 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.

[0083] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder Al.

[0084] The aluminum alloys described herein can be produced from a substantial portion of recycled scrap. In some embodiments, the aluminum alloys described herein can be produced from a combination of different recycled scrap materials. Recycled aluminum alloyAttorney Docket No. 108050-1527047 scrap (e.g., recycled scrap) can be obtained from various sources at all stages of the aluminum life cycle. In some cases, recycled scrap can refer to a collection of recycled metal. Recycled scrap can include materials recycled from any suitable source, such as from a metal production facility (e.g., a metal casting facility), from a metalworking facility (e.g., a production facility that uses metal products to create consumable products), or from post-consumer sources (e.g., regional recycling facilities). For example, internal scrap may be produced during production of an aluminum alloy in a metal casting facility (e.g., scrap from producing an aluminum ingot, billet, sheet, plate, etc.), customer scrap may be produced during stamping, milling, and other processes in a metalworking facility (e.g., scrap from creating can bodies, can ends, automobile parts, etc.), and post-consumer scrap may be produced from aluminum products used by consumers and collected at regional recycling facilities (e.g., used beverage cans, used automobile parts, etc.). Each of these types of recycled scrap can be a substitute for primary aluminum.

[0085] The aluminum alloys of the present disclosure can be fabricated from recycled content, including recycled brazing materials, end-of-life scrap, run-around scrap, and / or closed-loop scrap. The 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 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 aluminum alloy. All expressed in wt. % based on the total weight of the material used to cast the aluminum alloy.

[0086] Advantageously, the aluminum alloys described herein can be fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycled material). The recycled material used to fabricate the aluminum alloys can include a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer 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 %,Attorney Docket No. 108050-152704770 %, 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.

[0087] In some embodiments, the aluminum alloy described herein is produced from at least 40 wt. % end-of-life scrap having a Si content from 4 wt. % to 10 wt. % (e.g., Twitch scrap). In some embodiments, the aluminum alloy described herein is produced from at least 40 wt. % end-of-life scrap to at least 80 wt. % end-of-life scrap (e.g., from at least 50 wt. % to at least 80 wt. %, or from at least 60 wt. % to at least 80 wt. %). In some embodiments, the end-of-life scrap is Twitch scrap. The Twitch scrap comprises 4.0 - 10 wt. % Si, 0.4 - 1.0 wt. % Fe, 1.0 - 2.5 wt. % Cu, 0.1 - 0.3 wt. % Mn, 0.3 - 1.5 wt. % Mg, and 0.5 - 1.2 wt. % Zn.

[0088] In some embodiments, the aluminum alloy described herein is produced from at least 40 wt. % 6xxx run-around aluminum scrap (RAR scrap) and / or closed-loop aluminum scrap (CLR scrap) having a Si content from 0.6 wt. % to 0.8 wt. %. In some embodiments, the aluminum alloy described herein is produced from at least 40 wt. % CLR scrap and / or RAR scrap to at least 80 wt. % CLR scrap and / or RAR scrap (e.g., from at least 50 wt. % to at least 80 wt. %, or from at least 60 wt. % to at least 80 wt. %). In some embodiments, the 6xxx RAR and / or CLR scrap comprises 0.6 - 0.8 wt. % Si, 0.2 - 0.3 wt. % Fe, 0.1 - 0.8 wt. % Cu, 0.1 - 0.2 wt. % Mn, 0.5 - 0.8 wt. % Mg, and 0.02 - 0.1 wt. % Zn. In some embodiments, the aluminum alloy comprises up to 40 wt. % Twitch scrap and up to 40 wt. % RAR scrap and / or CLR scrap.

[0089] In some aspects, the aluminum alloy can be produced from up to 100 % recycled scrap (e.g., from 70 % to 100 %, from 80 % to 100 %, from 90 % to 100 %, or from 95 % to 100 %), based on the total weight of the aluminum alloy. All are expressed in wt. %.

[0090] The recycled content used to fabricate the 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 recycled material. All expressed in wt. % based on the total weight of the recycled material. Examples of non-4xxx seriesAttorney Docket No. 108050-1527047 aluminum alloys include Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, and 8xxx series aluminum alloys.

[0091] In some instances, the recycled material used to fabricate the 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.

[0092] In some instances, the recycled content used to fabricate the 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.

[0093] In some instances, the recycled content used to fabricate the 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.Attorney Docket No. 108050-1527047

[0094] The 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.

[0095] The 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.

[0096] Nonetheless, in embodiments, the aluminum alloys of the present disclosure can be fabricated from prime aluminum. The aluminum alloys can include prime aluminum 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 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 % prime aluminum, based on a total weight of material used to cast the aluminum alloy. However, in embodiments, prime aluminum alloy can be used in combination with the recycled scrap to produce the aluminum alloys described herein such as to minimize prime aluminum as discussed above. For example, up to 20 % prime aluminum (e.g., up to 18 %, up to 15 %, up to 12 %, up to 10 %, up to 8 %, up to 6 %, up to 4 %, up to 2 %, or up to 1 %) can be used to produce the aluminum alloys described herein. All are expressed in wt. %. In some embodiments, no prime aluminum alloy is used with the recycled scrap All expressed in wt. % based on the total weight of the material used to cast the aluminum alloy.

[0097] The aluminum alloys described herein, such as those that are fabricated using a mixed cladded alloy recycled material (e.g., a mixed cladded alloy, pre-consumer recycledAttorney Docket No. 108050-1527047 material), may be used in structures for automative applications (e.g., hood inner, vehicle floor, battery enclosure of electric vehicle).Methods of Making Aluminum Alloys

[0098] The aluminum alloys described herein can be cast into a cast product using a direct chill (DC) process or can be cast using a continuous casting (CC) process. The casting process is performed according to standards commonly used in the aluminum industry as known to one of skill in the art. The CC process may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters. In some examples, the casting process is performed by a CC process to form a slab, a strip, or the like. In some examples, the casting process is a DC casting process to form a cast product.

[0099] The cast product, slab, or strip can then be subjected to further processing steps. Optionally, the further processing steps can be used to prepare aluminum alloy products (e.g., sheets, shates, or plates). Such processing steps include, but are not limited to, a homogenization step, a hot rolling step, optionally a cold rolling step, and a continuous annealing and solution heat treatment (CASH) step or an anneal step. The processing steps are described below in relation to a cast product. However, the processing steps can also be used for a cast slab or strip, using modifications as known to those of skill in the art.

[0100] In a homogenization step, a cast product may be heated to a homogenization temperature, such as a temperature from 450 °C to 660 °C (e.g., from 450 °C to 650 °C, from 500 °C to 640 °C, from 550 °C to 630 °C, from 560 °C to 620 °C, from 570 °C to 610 °C, or from 580 °C to 600 °C, or from 500 °C to 560 °C, from 510 °C to 570 °C, from 540 °C to 565 °C,). For example, the cast product can be heated to a temperature of 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, 630 °C, 640 °C, 650 °C, or 660 °C. In some embodiments, the homogenization temperature is greater than 500 °C. In some embodiments, the homogenization temperature is greater than 530 °C. In some embodiments, the homogenization temperature is greater than 540 °C. In some embodiments, the homogenization temperature is greater than 550 °C. The cast product may then be allowed to soak (i.e., held at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time for the homogenization step, including the heating and soaking phases, can be up to 50 hours, up to 40 hours, up to 30 hours, up to 20 hours, up to 15 hours, or up to 10 hours, or any ranges or values therebetween.Attorney Docket No. 108050-1527047

[0101] Following a homogenization step, a hot rolling step can be performed. In some embodiments, the homogenized product is hot rolled directly after homogenization. In some embodiments, the product may undergo a separate pre-heating prior to hot rolling in a separate processing step. In some embodiments there is no homogenization step prior to pre-heating. The entry temperature to the hot rolling step can be the same as the homogenization temperature. In some embodiments, the pre-heating temperature is close to the homogenization temperature (e.g., between 500 °C and 570 °C). In some embodiments, the pre-heating temperature is lower than the homogenization temperature (e.g., between 390 °C and 520 °C). In some embodiments, the entry temperature prior to hot rolling is close to the homogenization temperature (e.g., between 500 °C and 550 °C). In some embodiments, the entry temperature prior to hot rolling is lower than the homogenization temperature (e.g., between 370 °C and 500 °C) The homogenized product can be hot rolled using a rolling mill to produce a hot rolled product. The homogenized product can be hot rolled at an initial hot rolling temperature ranging from 370 °C to 600 °C (e.g., from 370 °C to 430 °C, from 430 °C to 480 °C, from 480 °C to 520 °C, from 520 °C to 550 °C, or from 550 °C to 570 °C). For example, the homogenized product can be hot rolled at a hot rolling temperature of 370 °C, 380 °C, 390 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, 460 °C, 470 °C, 480 °C, 490 °C, 500 °C, 510 °C, 520 °C, 530 °C, 540 °C, 550 °C, 560 °C, 570 °C, 580 °C, 590 °C, or 600 °C.

[0102] The hot rolled product can be cold rolled using cold rolling mills into thinner products. The cold rolled product can have a gauge between 0.5 to 10 mm, e.g., between 0.7 to6.5 mm. Optionally, the cold rolled product can have a gauge of 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. The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to 95 % (e.g., up to 10 %, up to 20 %, up to 30 %, up to 40 %, up to 50 %, up to 60 %, up to 70 %, up to 80 %, up to 85 %, up to 90 %, or up to 95 % reduction) as compared to a gauge prior to the start of cold rolling. In some embodiments, the cold rolling step may include one or more cold rolling steps to achieve the desired gauge thickness reduction. However, it should be understood that, in embodiments, any one or more of the above gauges or reductions may be achieved by the hot rolling, and thus, in embodiments, the cold rolling may be optional. Optionally, the process for producing the aluminum alloy can include an inter-annealing step (e.g., before any cold rolling step, between one or more cold rolling steps) at a peak metal temperature from 300° C to 500° C, soaking for 0 hours to 20 hours.Attorney Docket No. 108050-1527047

[0103] Following hot rolling or cold rolling, the final gauge rolled product can be solution heat treated unlike conventional 4xxx series alloys. For example, the final gauge rolled product can be heated to a peak metal temperature for solution heat treatment. The solution heat treatment step may include heating the final gauge rolled product from room temperature to a peak metal temperature of from 400 ° C to 600 ° C or from 450° C to 580° C (e.g., from 460° C to 580° C, from 470° C to 570° C, from 480° C to 570° C, from 490° C to 570° C, or from 500° C to 570° C). The final gauge rolled product can soak at the peak metal temperature for a period of time. In certain aspects, the final gauge rolled product is allowed to soak for up to approximately 1 minute (e.g., from 0 second to 60 seconds inclusively) at the peak metal temperature. For example, the final gauge rolled product can be soaked at the peak metal temperature from 500° C to 560° C for 0 seconds, 5 seconds, 10 seconds, 15 seconds, 20 seconds, 25 seconds, 30 seconds, 35 seconds, 40 seconds, 45 seconds, 50 seconds, 55 seconds, 60 seconds, or anywhere in between. In some embodiments, the solution heat treatment step comprises soaking the final gauge rolled product for 0 seconds to 30 seconds at a peak metal temperature between 530° C to 560° C.

[0104] Optionally, after solution heat treatment or annealing, the final gauge product can be pre-aged. The pre-aging temperature can range from 50 °C to 150 °C to produce a pre-aged product. For example, the aluminum alloy product can be heated to a pre-aging temperature of 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, 110 °C, 120 °C, 130 °C, 140 °C, 150 °C, or anywhere in between. In other embodiments, the pre-ageing temperature ranges from 60 °C to 110 °C to produce a pre-aged product. After being heated to the pre-ageing temperature, the aluminum alloy product may then be held at the pre-ageing temperature for a period of time to form a preaged product. In some embodiments, the pre-aging step may involve holding the aluminum alloy product at the pre-aging temperature for up to 50 hours (e.g., up to 30 minutes, up to 5 hours, up to 10 hours, up to 20 hours, up to 30 hours, up to 40 hours, up to 50 hours, or anywhere in between).

[0105] In certain aspects, the final gauge rolled product is quenched after heat treatment. For example, the final gauge rolled product can be quenched directly after soaking at the peak metal temperature in the solution heat treatment step. The aluminum alloy can be quenched with air or water. In some embodiments, the quenching rate is from 5 K / s to 200 K / s.

[0106] In certain aspects, the solution heat treated product or the pre-aged product can be aged to a temper. The solution heat treated product or the pre-aged product can be naturally aged or artificially aged for a period of time to result in T temper. For example, the solutionAttorney Docket No. 108050-1527047 heat treated product or the pre-aged product can be aged to T4 temper, a T6 temper, a T8 temper, a T61 temper. In certain aspects, the final gauge rolled product provided in the T6 temper can be artificially aged (AA) at 100° C to 250° C (e.g., 100° C, 105° C, 110° C, 115° C, 120° C, 125° C, 130° C, 135° C, 140° C, 145° C, 150° C, 155° C, 160° C, 165° C, 170° C, 175° C, 180° C, 185° C, 190° C, 195° C, 200° C, 205° C, 210° C, 215° C, 220° C, 225° C, 230° C, 235° C, 240° C, 245° C, or 250° C) for a period of time. Optionally, the solution heat treated product or the pre-aged product can be artificially aged for a period from 15 minutes to 10 hours (e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, or 10 hours or anywhere in between) to result in the T6 temper.

[0107] In embodiments, the final gauge rolled product may be provided in O temper or an under-solutionized condition, either by utilizing the solution heat treatment discussed above, or by a batch anneal process. For instance, in embodiments, it may be desirable to provide the rolled product in an O temper or an under-solutionized condition. For instance, providing the rolled product in an O temper or an under-solutionized condition may improve the softness and bendability of the product, which may be desirable for application including automotive hood inners that benefit from such properties in order to provide greater pedestrian protection. Thus, in embodiments, providing the rolled product in an O temper or an under-solutionized condition may include a low temperature solution heat treatment which may be conducted at a peak metal temperature of 300° C to 500° C, (e.g. 310° C to 490° C, 320° C to 480° C, 330° C to 470° C, 340° C to 460° C, 350° C to 450° C, 360° C to 440° C, 370° C to 430° C, 380° C to 420° C, 390° C to 410° C, or any ranges or values therebetween). In embodiments, the rolled product may be soaked from 0 hours to 20 hours (e.g. 1 hour to 19 hours, 2 hours to 18 hours, 3 hours to 17 hours, 4 hours to 16 hours, 5 hours to 15 hours 6 hours to 14 hours, 7 hours to 13 hours, 8 hours to 12 hours, or any ranges or values therebetween).

[0108] The aluminum alloy described herein is suitable for use in the manufacturing of products formed by plastic forming processes such as stamping, creep forming, roll forming, and stretch forming. For example, the aluminum alloy described herein can produce a roll formed product. The aluminum alloy described herein is particularly useful in roll forming applications where an aluminum alloy sheet is subjected to continuous bending operations through a consecutive set of rolls to produce a roll formed product.Attorney Docket No. 108050-1527047Method of Remote Laser Welding an Aluminum Alloy

[0109] In some embodiments, a method of remote laser welding an aluminum alloy product produced from the aluminum alloys described herein is provided. The method includes supplying an aluminum alloy product comprising the aluminum alloy composition described herein. For example, the aluminum alloy composition may be any one of the compositions provided in Tables 1-15. The aluminum alloy product can be a rolled product. For example, the aluminum alloy product can be a rolled aluminum alloy sheet, plate, or shate. In some embodiments, the aluminum alloy product is a monolithic product (e.g., a single non-composite alloy).

[0110] The method includes joining one or more additional alloy products to the aluminum alloy product comprising the composition described herein by remote laser welding without filler wire. The aluminum alloy product comprising the composition described has improved weldability, in particular during remote laser welding without filler wire, as well as excellent formability and corrosion resistance. In some embodiments, the method includes welding by superposition for welding in an end-to-end configuration.Properties

[0111] Alloys discussed herein may provide excellent formability and strength properties. Surprisingly, the aluminum alloys, such as the alloy discussed herein, may achieve similar properties to 6xxx aluminum alloys, allowing the alloys discussed herein to be well suited for automotive applications. Namely, by utilizing the methods and alloys discussed herein, alloying elements, such as magnesium, copper, and / or silicon may allow for formation of strengthening precipitates (e.g. Mg2Si, P" in embodiments) during aging after the solution heat treatment. In addition, by utilizing the methods and alloys discussed herein, alloying elements, such as manganese and / or iron may allow refined grain structure and weak texture after solution heat treatment. Thus, the aluminum alloy discussed herein may exhibit excellent properties after the solution heat treatment, due at least in part to the presence of alloying elements from the recycled content.

[0112] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength (RP0.2) of 80 MPa or greater when in a T4 temper .g., 80 to 200 MPa, from 100 MPa to 180 MPa, from 120 MPa to 160 MPa, from 150 MPa to 175 MPa, or from 130 MPa to 140 MPa, or any ranges or values therebetween). For example, an aluminum alloy product produced from the aluminum alloys described herein can have aAttorney Docket No. 108050-1527047 yield strength of 110 MPa or greater, 120 MPa or greater, 130 MPa or greater, or 140 MPa or greater, when in a T4 temper. In some cases, the yield strength is from 100 MPa to 140 MPa (e.g., from 110 MPa to 140 MPa, from 120 MPa to 140 MPa, or from 130 MPa to 140 MPa), or anywhere in between, when in a T4 temper and in embodiments, at a 1 mm final gauge. The aluminum alloy products described herein can exhibit the yield strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0113] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have an ultimate tensile strength (Rm) of about 160 MPa or greater (e.g., from 170 MPa to 350 MPa, from 180 MPa to 340 MPa, from 190 MPa to 330 MPa, from 200 MPa to 300 MPa, from 210 MPa to 300 MPa, from 220 MPa to 300 MPa, from 230 MPa to 300 MPa, from 240 MPa to 290 MPa, from 250 MPa to 280 MPa, or from 295 MPa to 330 MPa, or any ranges or values therebetween) when in a T4 temper. For example, the aluminum alloy products can have an ultimate tensile strength of 210 MPa or greater, 220 MPa or greater, 230 MPa or greater, 240 MPa or greater, 250 MPa or greater, 255 MPa or greater, 260 MPa or greater, 265 MPa or greater, 270 MPa or greater, 275 MPa or greater, or 280 MPa or greater, when in a T4 temper. In some cases, the ultimate tensile strength is from 200 MPa to 300 MPa (e.g., from 210 MPa to 300 MPa, from 215 MPa to 290 MPa, or from 220 MPa to 280 MPa), or anywhere in between, when in a T4 temper. The aluminum alloy products described herein can exhibit the ultimate tensile strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0114] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 15% or greater when in a T4 temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 16% or greater, 17% or greater, 18% or greater, 19% or greater, 20% or greater, 21% or greater, 22% or greater, 23% or greater, 24% or greater, 25% or greater, 26% or greater, 28% or greater, or 29% or greater when in a T4 temper. In some cases, the uniform elongation is from 20% to 30% (e.g., from 20% to 30%, from 21% to 30%, from 22% to 30%, 23% to 30%, 24% to 30%, or from 25% to 29%), or anywhere in between, when in a T4 temper. The aluminum alloy products described herein can exhibit the uniform elongation as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.Attorney Docket No. 108050-1527047

[0115] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation (Ag) of 15% or greater when in a T4 temper by ASTM E8 testing method with 50mm gauge length. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation of 16% or greater, 17% or greater, 18% or greater, 19% or greater, 20% or greater, 21% or greater, 22% or greater, 23% or greater, or 24% or greater, when in a T4 temper. In some cases, the total elongation is from 15% to 28% (e.g., from 16% to 28%, from 18% to 27%, from 19% to 25%, from 20% to 24%, from 20% to 23%, or from 23% to 25%), or anywhere in between, when in a T4 temper. The aluminum alloy products described herein can exhibit the total elongation as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0116] In some examples, an aluminum alloy product (e.g., an aluminum alloy sheet) produced from the aluminum alloys described herein can have a yield strength of 180 MPa or greater when in a T8 temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 190 MPa or greater, 200 MPa or greater, 210 MPa or greater, 220 MPa or greater, 230 MPa or greater, 240 MPa or greater, 250 MPa or greater, 260 MPa or greater, 270 MPa or greater, or 280 MPa or greater when in a T8 temper. In some cases, the yield strength is from 180 MPa to 350 MPa (e.g., from 200 MPa to 320 MPa, from 220 MPa to 300 MPa, from 240 MPa to 280 MPa, or from 250 MPa to 275 MPa), or anywhere in between, when in a T8 temper. The aluminum alloy products described herein can exhibit the yield strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0117] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have an ultimate tensile strength of about 280 MPa or greater when in a T8 temper. For example, the aluminum alloy products can have an ultimate tensile strength of 290 MPa or greater, 300 MPa or greater, 310 MPa or greater, 320 MPa or greater, or 330 MPa or greater when in a T8 temper. In some cases, the ultimate tensile strength is from 280 MPa to 340 MPa (e.g., from 290 MPa to 335 MPa, from 295 MPa to 330 MPa, or from 300 MPa to 325 MPa), or anywhere in between. The aluminum alloy products described herein can exhibit the ultimate tensile strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.Attorney Docket No. 108050-1527047

[0118] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 8% or greater when in a T8 temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 9% or greater, 10% or greater, 11% or greater, 12% or greater, 13% or greater, or 14% when in a T8 temper. In some cases, the uniform elongation is from 8% to 24% (e.g., from 9% to 23%, from 10% to 22%, from 11% to 21%, from 12% to 20%, from 13% to 19%, from 14% to 18%, or from 15% to 17%), or anywhere in between, when in a T8 temper. The aluminum alloy products described herein can exhibit the uniform elongation as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0119] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation (Ag) of 6% or greater when in a T8 temper by ASTM E8 test method with 50mm gauge length. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation of 7% or greater, 8% or greater, 9% or greater, 10% or greater, 11% or greater. 12% or greater, 13% or greater, 14% or greater, 15% or greater, 16% or greater, 17% or greater, 18% or greater, 19% or greater, 20% or greater, 21% or greater, or 22% or greater, when in a T6 temper. In some cases, the total elongation is from 6% to 28% (e.g., from 7% to 28%, from 8% to 28%, from 8% to 28%, from 8% to 28%, from 8% to 26%, or from 8% to 25%), or anywhere in between, when in a T8 temper. The aluminum alloy products described herein can exhibit the total elongation as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0120] In some examples, an aluminum alloy product (e.g., an aluminum alloy sheet) produced from the aluminum alloys described herein can have a yield strength (RP0.2) of 200 MPa or greater when in a T6 temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 210 MPa or greater, 220 MPa or greater, 230 MPa or greater, 240 MPa or greater, 250 MPa or greater, 260 MPa or greater, 270 MPa or greater, 280 MPa or greater, 290 MPa or greater, 300 MPa or greater, 310 MPa or greater, 320 MPa or greater, or 330 MPa or greater when in a T8 temper. In some cases, the yield strength is from 200 MPa to 350 MPa (e.g., from 230 MPa to 340 MPa, from 240 MPa to 330 MPa, from 250 MPa to 320 MPa, or from 260 MPa to 310 MPa), or anywhere in between, when in a T6x temper. The aluminum alloy products described herein can exhibit theAttorney Docket No. 108050-1527047 yield strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0121] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have an ultimate tensile strength of about 260 MPa or greater when in a T6 temper. For example, the aluminum alloy products can have an ultimate tensile strength of 270 MPa or greater, 280 MPa or greater, 290 MPa or greater, 300 MPa or greater, 310 MPa or greater, 320 MPa or greater, 330 MPa or greater, 340 MPa or greater, or 350 MPa or greater when in a T6 temper. In some cases, the ultimate tensile strength is from 260 MPa to 400 MPa (e.g., from 270 MPa to 380 MPa, from 280 MPa to 360 MPa, or from 290 MPa to 340 MPa), or anywhere in between. The aluminum alloy products described herein can exhibit the ultimate tensile strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0122] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation of 6% or greater by ASTM E8 test method with 50mm gauge length when in a T6 temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation of 7% or greater, 8% or greater, 9% or greater, 10% or greater, 11% or greater, 12% or greater, 13% or greater, or 14% or greater, 15% or greater, 16% or greater, or 17% or greater, when in a T6 temper. In some cases, the total elongation is from 6% to 30% (e.g., from 7% to 29%, from 8% to 28%, from 8% to 27%, from 8% to 26%, from 8% to 24% or from 8% to 20%), or anywhere in between, when in a T6 temper. The aluminum alloy products described herein can exhibit the total elongation as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0123] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 8% or greater when in a T6 temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 8% or greater, 9% or greater, 10% or greater, 11% or greater, 14% or greater, 15% or greater, 16% or greater, 17% or greater, 18% or greater, 19% or greater, or 20% or greater, when in a T6 temper. In some cases, the uniform elongation is from 10% to 28% (e.g., from 11% to 28%, from 12% to 28%, from 13% to 28%, from 14% to 27%, from 15% to 26%, or from 16% to 25%), or anywhere in between, when in a T6 temper. The aluminum alloy products described herein can exhibit the uniform elongation as describedAttorney Docket No. 108050-1527047 herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0124] In some examples, an aluminum alloy product (e.g., an aluminum alloy sheet) produced from the aluminum alloys described herein can have a yield strength (RP0.2) of less than 100 MPa when in an O temper or an under-solutionized condition. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 100 MPa or less, 95 MPa or less, 90 MPa or less, 85 MPa or less, 80 MPa or less, 75 MPa or less, 70 MPa or less, 65 MPa or less, 60 MPa or less when in an O temper. In some cases, the yield strength is from 0 MPa to 100 MPa (e.g., from 10 MPa to 80 MPa, from 20 MPa to 75 MPa, from 25 MPa to 70 MPa, or from 30 MPa to 65 MPa), or anywhere in between, when in an O temper or an under-solutionized condition. The aluminum alloy products described herein can exhibit the yield strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0125] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 20% or greater when in an O temper or an under-solutionized condition. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 20% or greater, 21% or greater, 22% or greater, 23% or greater, 24% or greater, 25% or greater, 26% or greater, or 27% or greater, when in an O temper. In some cases, the uniform elongation is from 20% to 30% (e.g., from 21% to 29%, from 22% to 28%, from 23% to 27%, from 24% to 26%), or anywhere in between, when in an O temper or an under-solutionized condition. The aluminum alloy products described herein can exhibit the uniform elongation as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0126] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a bend angle P as measured according to the test set forth in Verband der Automobilindustrie (VDA) Test No. 238-100 (2023) from 10 ° to 140 °(e.g., from 10 ° to 135 °, from 20 ° to 120 °, or from 30 ° to 110 °). For example, an aluminum alloy product produced from the aluminum alloys described herein can have a VDA bending angle P of about 30 °, 35 °, 40 °, 45 °, 50 °, 55 °, 60 °, 65 °, 70 °, 75 °, 80 °, 85 °, 90 °, 95 °, 100 °, 105 °, 110 °, 115 °, 120 °, 125 °, including when subjected to 10 % pre-strain when in a T4 temper, orAttorney Docket No. 108050-1527047 anywhere in between. The lower VDA bending beta angles of the aluminum alloy product described herein provides improved flexibility of the product.

[0127] In some examples, the minimum R / t ratio (i.e., f-factor) of an aluminum alloy product produced from the aluminum alloys described herein can be 1.6 or less (e.g., about 1.5 or less, about 1.4 or less, about 1.3 or less, about. 1.2 or less, about 1.1 or less, about 1.0 or less, about 0.90 or less, about 0.80 or less, about 0.70 or less, about 0.60 or less, about 0.50 or less, or about 0.40 or less). The R / t ratio provides an estimate of the flexibility of the material. The bendability is evaluated based on the R / t ratio, where R is the radius of the tool (mold) used, and t is the thickness of the material. A lower R / t ratio indicates better material flexibility.

[0128] The intergranular corrosion of alloys described herein can be measured according to ISO 11846B. For example, pursuant to testing method ISO 11846B, aluminum alloy samples are etched with aqueous base (e.g., for two minutes in 5% aqueous NaOH at 60 °C), treated with acid (e.g., 69% HNO3 at room temperature), and subsequently immersed in acidic solution (e.g., 30g / L NaCl and lOmL / L of 37% HC1 for 24 hours at a volume-to-surface ratio of 5 mL solution per cm2of the aluminum alloy sample). The intergranular corrosion of aluminum alloy samples are then determined using cross section analysis and an intergranular corrosion automatic evaluation tool. In some examples, the aluminum alloy exhibits an intergranular corrosion depth of 290 - 370 pm when in a T6 temper (e.g., from 290 - 370 pm or from 290 - 330 pm) as measured according to ISO 11846B. In some examples, the aluminum alloy exhibits an intergranular corrosion depth of less than 330 pm when in a T6 temper as measured according to ISO 11846B. In some examples, the aluminum alloy exhibits an intergranular corrosion depth of 230 - 330 pm when in a T8x temper (e.g., from 230 - 330 pm or from 230 - 270 pm) as measured according to ISO 11846B. In some examples, the aluminum alloy exhibits an intergranular corrosion depth of less than 330 pm when in a T8x temper as measured according to ISO 11846B.Uses and Applications

[0129] Due at least in part to the excellent strength and formability characteristics, the alloys discussed herein may be well suited for use in automotive and / or transportation applications, including motor vehicle, aircraft, and railway applications, or any other desired application. In some examples, the alloys and methods can be used to prepare motor vehicle body part products, such as skin and structural automotive applications, bumpers, inner panels, outer panels, side panels, inner hoods, outer hoods, battery enclosures of electric vehicles, orAttorney Docket No. 108050-1527047 trunk lid panels. The aluminum alloys and methods described herein can also be used in aircraft or railway vehicle. Furthermore, due to the unique properties obtained, such as in an O temper or a T4 temper, the alloys discussed herein may also be well suited for motor vehicle body part products that meet pedestrian protection requirements.EXAMPLESExample 1

[0130] The aluminum alloy compositions of Examples Alloys 1-9 were evaluated to determine the effect of different alloying elements on the properties of an aluminum alloy produced from high Si content recycled aluminum alloy materials. The 6xxx series aluminum alloys aluminum alloy compositions described herein are classified as comprising high amounts of Si (e.g., 0.80 - 4.60 wt. %), and can be prepared from at least 80 wt. % high Si content aluminum alloy scrap, such as end-of-life Twitch aluminum scrap and 6xxx run-around scrap. Table 16 below shows exemplary compositional ranges of prime aluminum and recycled aluminum alloy scrap (Twitch and 6xxx mixed scrap (e.g., different types of mixed 4xxx series aluminum alloys)) that can be used to prepare the alloys described herein.

[0131] Sample aluminum alloys were tested to determine the properties of the aluminum alloys described herein. Example Alloys 1-9 were prepared by direct chill casting to produce cast products having the dimensions of 220mm x 70 mm. The cast products were then homogenized at a temperature between 530 °C and 550 °C for approximately fourteen hours to produce homogenized products, the homogenized products were hot rolled to 9.5 mm at anAttorney Docket No. 108050-1527047 exit temperature of 400 °C to produce hot rolled products, the hot rolled products were coiled at 400 °C, the coiled hot rolled products were cooled from 400 °C to 25 °C over twenty-four hours, and the coiled hot rolled products were cold rolled to a thickness of the 1 mm to produce final gauge rolled products. The final gauge rolled products were solutionized in a sand bath at a temperature of about 530 °C to 550 °C for sixty seconds, then quenched with water, and preaged for one hour at 100 °C. The final gauge rolled products were then aged to a T4, T6, or T8x temper. Comparative Example 1 is a high strength commercially available 6xxx series aluminum alloy that has a lower Si content than the aluminum alloys described herein. Table 17 provides the aluminum alloy composition for each of Comparative Example 1 and Example Alloys 1-9.

[0132] As shown in Table 17, Comparative Example 1 is a 6xxx series aluminum including less than 1.7 wt. % Si. As discussed herein, and shown in Table 12 above, end-of-life Twitch and run-around scrap aluminum contains high amounts of Si (e.g., end-of-life Twitch scrap contains from 4 to 10 wt. % Si). The aluminum alloys described herein have a carefully controlled composition that achieves similar or better strength and bendability properties as conventional 6xxx series aluminum alloys despite having higher Si content than conventional 6xxx series aluminum alloys. Beneficially, the aluminum alloys described herein promotes circularity for high Si content recycled aluminum alloys because the tailored compositions can be prepared from at least 80 % scrap aluminum.Attorney Docket No. 108050-1527047

[0133] Accordingly, the mechanical properties and microstructure of Example Alloys 1-9 were investigated. Table 18 below contains a summary of mechanical properties that are suitable for skin and structural applications.

[0134] FIG. 1 contains scanning election microscopy images showing the microstructure of Comparative Example 1, and Example Alloys 1, 3, 5, and 9. As can be seen in FIG. 1, increasing Si content correlates to an increase in the number of constituents as well as the size of the constituents.

[0135] FIG. 2 contains a graph showing the effect of various alloying elements on the Ag (%) value and the RP0.2 (MPa) value, when in a T4 temper, in Example Alloys 1-9 and Comparative Example 1. As can be seen in FIG. 2, increasing Si content corresponds to a decrease in Ag value, whereas the addition of Fe, Mg, Cu, and Zn alloying elements increases the RP0.2 value of the aluminum alloy.

[0136] FIG. 3 contains a graph showing the relationship between the DC Bending angle (T4, P °) and the F-factor (T4, 15 % pre-strain) for Example Alloys 1-9 and Comparative Example 1. As can be seen in FIG. 3, Fe content affects the bending properties of the aluminum alloys, where an increase in Fe content correlates to an increase in the DC bending angle. Without being limited by theory, adjusting the Fe content affects the amount and type of intermetallic species in the Example Alloys, thereby affecting the bendability of the Example Alloys.

[0137] FIG. 4A-4D contains graphs showing the effect of Si, Fe, Mg, Cu, and Zn alloying elements on n values and r values of Example Alloys 1-9 and Comparative Example 1. FIG.Attorney Docket No. 108050-15270474A, contains a graph showing the nio-i5(avg) value (y-axis) of Example Alloys 1, 4, 7, and Comparative Example 1 in the longitudinal (L), diagonal (D), and transverse (T) directions. FIG. 4B, contains a graph showing the nio-i5(avg) value (y-axis) of Example Alloys 2, 3, 5, 6, 8, and 9 in the longitudinal (L), diagonal (D), and transverse (T) directions. FIG. 4C, contains a graph showing the rs-i2(avg) value (y-axis) of Example Alloys 1, 4, 7, and Comparative Example 1 in the longitudinal (L), diagonal (D), and transverse (T) directions. FIG. 4D, contains a graph showing the rs-i2(avg) value (y-axis) of Example Alloys 2, 3, 5, 6, 8, and 9 in the longitudinal (L), diagonal (D), and transverse (T) directions.

[0138] As can be seen in FIG. 4A-4D, increasing each of the aforementioned alloy elements lowered n values, and Si had the largest impact on n values. In contrast, increasing Si improved r values and isotropy of the Example Alloys, whereas the addition of Fe, Mg, Cu, and Zn increased r values but with increased anisotropy.

[0139] FIG. 5 contains a graph showing the RP0.2 value (T8x, MPa, 2% 185 °C 20 minutes) versus the total elongation Ag (T4, %). As can be seen in FIG. 5, both Example Alloys 1 and 4 alloys have favorable properties for both skin and structural applications, where both alloys have a total elongation Ag of greater than 20%, as well as a RP0.2 value of greater than 250 MPa.Example 2

[0140] Example Alloys 10-16 are 6xxx series aluminum alloys with varied alloy compositions to evaluate the effect of Mg with Si content from 1.7 to 2.6 wt. %, and can be prepared from at least 80 wt. % high Si content recycled aluminum alloy scrap, such as end- of-life Twitch aluminum scrap and 6xxx run-around scrap.

[0141] Sample aluminum alloys were tested to determine the properties of the aluminum alloys described herein. Example Alloys 10-16 were prepared according to the methods described herein. Table 15 provides the aluminum alloy composition for each Example Alloys 10-16.Attorney Docket No. 108050-1527047Table 15.Name Si Fe Cu Mn Mg ZnExample 10 1.93 0.31 0.39 0.20 0.44 0.204Example 11 1.93 0.31 0.39 0.20 0.60 0.204Example 12 2.15 0.30 0.39 0.20 0.28 0.195Example 13 2.30 0.31 0.42 0.20 0.45 0.200Example 14 2.27 0.31 0.42 0.20 0.60 0.199Example 15 2.55 0.31 0.40 0.20 0.43 0.202Example 16 2.54 0.30 0.40 0.20 0.58 0.194

[0142] Comparative Example 1, and Example Alloys 1, 2, and 10-16 were plotted in a graph, FIG. 6, showing the effect of Mg content on the RP0.2 value (MPa) where increasing Mg content directly correlates to increased RP0.2 values, where the relationship between Mg content and the RP0.2 value can be represented by the following equation:RP0.2 (MPa) = 103.6 + 70.50 Mg

[0143] Thus, increased Mg content directly correlates with increased yield strength, and could be increased up to ca. 0.45 wt. %. However, high Mg content ca. 0.45 wt. % could negatively impact formability (e.g., where the F-factor would be greater than 1). FIG. 7 contains a graph showing the effect of Mg content on F factor values (T4, 15 % pre-strain) in Example Alloys 1-2, Example Alloys 10-16, and Comparative Example 1, where an Mg content of 0.45 wt. % or less corresponds to F factor values at or below 1.0, where the relationship between the Mg content (wt. %) and the F-factor can be expressed by the following equation:F, (T4, 15 % pre-strain) = 0.3333 = 1.544 MgAs can be seen in FIG. 7, an Mg content between ca. 0.3 wt. % and ca. 0.6 wt. % contributes to desirable formability properties for skin (ca. less than 0.7) and structural crush (ca. less than 1.1) applications.

[0144] FIG. 8 contains a graph showing the RP0.2 value (MPa) versus the total elongation Ag (%) of Example Alloys 10-16, Example Alloys 1 and 2, and Comparative Alloy 1. While increasing Mg content from ca. 0.3 wt. % to 0.6 wt. % correlates to increasing RP0.2 values, increasing Mg content has minimal effect on the total elongation of the investigated alloys.

[0145] FIG. 9 contains a graph showing the RP0.2 value (MPa) versus the P bending angle (°) (T4, DC) of Example Alloys 10-16, Example Alloys 1 and 2, and Comparative Alloy 1,Attorney Docket No. 108050-1527047 where increasing Mg content correlated to increased P bending angle, demonstrating an inverse relationship between the RP0.2 value and the P bending angle (°).

[0146] Bending is a limiting factor in designing aluminum alloy produced from high Si content recycled aluminum alloy scrap, where P bending angles of ca. less than 110° are beneficial for structural crush applications. As can be seen in FIG. 9, all of the Example Alloys have a P bending angle of less than 110°, and increased yield strength generally correlates with increased P bending angle, and high Si content of up to 4.5 wt. % can be tolerated while maintaining a balance of strength and bending properties for structural crush applications.

[0147] FIG. 10A (left) contains a graph showing the RP0.2 value as measured in a T6 temper versus total elongation Ag (%) of Example Alloys 10-16, Example Alloys 1 and 2, and Comparative Alloy 1. FIG. 10A (right) contains a graph showing the RP0.2 value as measured in a T8x temper versus total elongation Ag (%) Example Alloys 10-16, Example Alloys 1 and 2, and Comparative Alloy 1. FIG. 10B (left) contains a graph showing the Rm value as measured in a T6 temper versus total elongation Ag (%) of Example Alloys 10-16, Example Alloys 1 and 2, and Comparative Alloy 1. FIG. 10B (right) contains a graph showing the Rm value as measured in a T8x temper versus total elongation Ag (%) of Example Alloys 10-16, Example Alloys 1 and 2, and Comparative Alloy 1.

[0148] As can be seen in FIG. 10A-10B, Example Alloys having an Si content of up to ca. 2.5 wt. %, when Fe content is ca. less than 0.3 wt. % and Mg content is ca. less than 0.45 wt. %, exhibit a favorable combination yield strength and elongation in both a T6 and T8x temper for skin and structural applications. Example alloys having an RP0.2 of less than about 285 MPa and an Rmof less than about 350 MPa can beneficially be used in structural applications, where these Example Alloys can be shaped into aluminum alloy components via cold forming, for example. Therefore, while many alloys are formed in the T4 temper for structural applications, the Example Alloys exhibit a beneficial combination of strength and elongation at the T6 and T8x tempers for structural applications.

[0149] As can be seen in FIG. 10A-10B, Example Alloys having a Si content of less than about 2.5 wt., when the Fe content is ca. less than 0.3 wt. % and Mg content is between about 0.45 wt. % and 0.6 wt. %, exhibit favorable yield strength and elongation properties in a T6 temper for structural applications.

[0150] FIG. 11 contains a graph comparing RP0.2 values of Example Alloys in a T6 temper (180 °C, 10 hours) and a T8x temper (2%, 185 °C, 20 minutes) versus the P bending angle (°)(DC). As can be seen in FIG. 11, and without being limited by theory, the Example AlloysAttorney Docket No. 108050-1527047 display lower P bending angles in a T8x temper at similar RP0.2 values than when in a T6 temper.

[0151] While discussed above, it should be clear that while the examples discuss modifying the alloy of the present specification, the present specification also contemplates utilizing high silicon alloys (0.8 - 4.6 wt.%) treated with the unique solution heat treatment discussed herein in order to improve the properties of the alloy across the full spectrum of the silicon amounts discussed herein.Example 3

[0152] Example 17 was formed using the alloy set forth in Table 20 and formed from brazing scrap. The alloy was cast using direct chill (DC) casting, homogenized at 450-550° C, hot rolled, and cold rolled to 0.8-3.5 mm gauge, as discussed above. The cold rolled product of Example 17 was then solution heat treated as discussed herein at temperatures of 520° C to 540° C. The solution heat treated product was then aged to form a T6 tempered alloy using artificial aging at 120-250 °C for 0.5-15 hr.Table 20.Name Si Fe Cu Mn Mg Ti CrExample 17 1.9 0.33 0.47 0.84 0.34 0.06 0.02

[0153] The alloy product of Example 17 was then tested for various properties shown below in Tables 21 and 22.Attorney Docket No. 108050-1527047

[0154] As shown, the product of Example 17 exhibited a yield strength (YS) of greater than 220 MPa and a uniform elongation (UE) of greater than 10%. Thus, Example 17 exhibits that the alloys of the present specification form products with excellent strength and formability, even at high levels of silicon. Further, Example 17 in T6 temper was tested against a commercial 6014 series alloy to illustrate the beneficial properties of the aluminum alloys discussed herein. As shown in FIG. 12, the product of Example 17 had a maximum pit depth when evaluated for intergranular corrosion depth (IGC) performance of 383 pm, whereas the commercial sample had a mas depth of 361 pm. Thus, as discussed herein, the samples of the present technology may exhibit properties similar to 6xxx alloys, which may allow for improved recyclability by utilizing the alloys discussed herein in applications typically dominated by 6xxx alloys which are intolerant to increased silicon levels.

[0155] In addition, Table 22 shows that the alloys of the present specification exhibit excellent strength and formability in different tempers, including T8 and O. Namely, the products of Table 22 were formed in the same manner discussed above, except that the samples were aged to a T8 temper or an O temper instead of a T6 temper.

[0156] As illustrated, the product of Example 17 in an O temper (also referred to as under- solutionized condition) exhibited a yield strength of less than 80 MPa and a uniform elongation of greater than 18%, as well as an ultimate tensile strength of greater than 150 MPa. Further, the product of Example 17 in a T8 temper exhibited a uniform elongation of greater than 10%. Thus, it is clear that the products of the present specification exhibit excellent strength and formability characteristics at a variety of tempers.Attorney Docket No. 108050-1527047ILLUSTRATIVE ASPECTS

[0157] 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”).

[0158] Aspect 1 : An aluminum alloy comprising: 0.8 wt. % to 2.7 wt. % silicon, 0.0 wt. % to 0.9 wt. % iron, 0.05 wt. % to 0.9 wt. % copper, 0.4 wt. % to 1.4 wt. % manganese, 0.05 wt.% to 0.7 wt.% magnesium, up to 0.4 wt. % chromium, up to 0.4 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum; and wherein the aluminum alloy comprises a uniform elongation of greater than or about 15% in a T4 temper or an O temper or an under-solutionized condition.

[0159] Aspect 2: The alloy of aspect 1, wherein the 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.

[0160] Aspect 3: The alloy of aspect 1 or 2, 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.

[0161] Aspect 4: The alloy of any one of aspects 1 to 3, wherein the aluminum alloy comprises at least 70 wt. % recycled material, and wherein at least 55 wt. % of the recycled material is a mixed cladded alloy recycled material.

[0162] Aspect 5: The alloy of any one of aspects 1 to 4, comprising 0.9 wt. % to 2.6 wt. % silicon, 0.0 wt. % to 0.8 wt. % iron, 0.07 wt. % to 0.8 wt. % copper, 0.5 wt. % to 1.3 wt. % manganese, 0.07 wt.% to 0.6 wt.% magnesium, up to 0.3 wt. % chromium, up to 0.3 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum.

[0163] Aspect 6: The alloy of any one of aspects 1 to 5, comprising: 1.0 wt. % to 2.5 wt. % silicon, 0.01 wt. % to 0.7 wt. % iron, 0.1 wt. % to 0.7 wt. % copper, 0.6 wt. % to 1.2 wt. % manganese, 0.1 wt.% to 0.5 wt.% magnesium, up to 0.2 wt. % chromium, up to 0.2 wt. % zinc, up to 0.2 wt. % titanium, up to 0.2 wt. % of impurities, and aluminum.

[0164] Aspect 7: The alloy of any one of aspects 1 to 6, wherein the aluminum alloy comprises a yield strength of greater than or about 120 MPa in a T4 temper.

[0165] Aspect 8: The alloy of any one of aspects 1 to 7, wherein the aluminum alloy comprises a yield strength of less than or about 80 MPa in an O temper or an under-solutionized condition.Attorney Docket No. 108050-1527047

[0166] Aspect 9: The alloy of any one of aspects 1 to 8, wherein the aluminum alloy comprises a yield strength of greater than or about 220 MPa in a T8 temper.

[0167] Aspect 10: The alloy of any one of aspects 1 to 9, wherein the aluminum alloy comprises a yield strength of greater than or about 250 MPa in a T6 temper.

[0168] Aspect 11 : A product fabricated with the aluminum alloy of any one or aspects 1 to 10, wherein the product comprises a structural automotive part.

[0169] Aspect 12: A method of producing an aluminum alloy comprising: casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises 0.8 wt. % to 2.7 wt. % silicon, 0.0 wt. % to 0.9 wt. % iron, 0.05 wt. % to 0.9 wt. % copper, 0.4 wt. % to 1.4 wt. % manganese, 0.05 wt.% to 0.7 wt.% magnesium, up to 0.4 wt. % chromium, up to 0.4 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum, optionally homogenizing and / or pre-heating the cast product; hot rolling the optionally homogenized and / or pre-heated product to produce a hot rolled product; optionally cold rolling the hot rolled product and optionally inter-annealing to produce a cold rolled product; solution heat treating or annealing the final gauge rolled product, optionally pre-aging the solution heat treated product, and optionally artificial aging of the solution heat treated product or the pre-aged product.

[0170] Aspect 13 : The method of aspect 12, further comprising aging the final gauge rolled product to a T temper.

[0171] Aspect 14: The method of aspect 12 or 13, wherein the T temper is a T4 temper, a T6 temper, or a T8 temper.

[0172] Aspect 15: The method of any one of aspects 12 to 14, further comprising treating the product to an O temper or an under-solutionized condition.

[0173] Aspect 16: The method of any one of aspects 12 to 15, wherein the cast product is cast from an aluminum alloy comprising one or more of 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.

[0174] Aspect 17: The method of any one of aspects 12 to 16, wherein the cast product is cast from an aluminum alloy comprising at least 70 wt. % recycled material, and wherein at least 55 wt. % of the recycled material is a mixed cladded alloy recycled material.

[0175] Aspect 18: The method of any one of aspects 12 to 17, wherein the cast product is cast from an aluminum alloy comprising less than 20 wt. % prime aluminum.Attorney Docket No. 108050-1527047

[0176] Aspect 19: A product fabricated with the aluminum alloy of any one of aspects 1 to 11 or formed according to the method of any one of aspects 12 to 18.

[0177] Aspect 20: The product of aspect 19, wherein the product comprises a structural automotive part.

[0178] Illustration 1 is an aluminum alloy comprising 1.70 - 4.50 wt. % Si, 0.10 - 0.60 wt. % Fe, up to 0.60 wt. % Mn, up to 0.90 wt. % Mg, up to 1.20 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al; wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.50 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from less than 20 wt. % prime aluminum.

[0179] Illustration 2 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 4.50 wt. % Si, 0.40 - 0.60 wt. % Fe, up to 0.60 wt. % Mn, 0.60 - 0.90 wt. % Mg, 0.75 - 1.20 wt. % Cu, up to 0.30 wt. % Cr, 0.40 - 0.60 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0180] Illustration 3 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 4.50 wt. % Si, 0.40 - 0.60 wt. % Fe, up to 0.60 wt. % Mn, up to 0.90 wt. % Mg, up to 1.20 wt. % Cu, up to 0.30 wt. % Cr, up to 0.60 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0181] Illustration 4 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 2.50 - 4.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0182] Illustration 5 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 2.50 - 4.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, up to 0.45 wt. % Mg, up to 0.45 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0183] Illustration 6 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 2.50 wt. % Si, 0.40 - 0.50 wt. % Fe, up to 0.30 wt. % Mn, up to 0.60 wt. % Mg, up to 0.75 wt. % Cu, up to 0.30 wt. % Cr, up to 0.40 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0184] Illustration 7 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 2.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30Attorney Docket No. 108050-1527047 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0185] Illustration 8 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 2.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.30 wt. % Mn, 0.45 - 0.60 wt. % Mg, 0.40 - 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0186] Illustration 9 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 2.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.20 wt. % Mn, up to 0.45 wt. % Mg, up to 0.45 wt. % Cu, up to 0.30 wt. % Cr, up to 0.20 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0187] Illustration 10 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 4.00 - 4.50 wt. % Si, 0.25 - 0.35 wt. % Fe, up to 0.40 wt. % Mn, up to 0.60 wt. % Mg, 0.30 - 0.40 wt. % Cu, up to 0.30 wt. % Cr, up to 0.30 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0188] Illustration 11 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.70 - 4.50 wt. % Si, 0.10 - 0.50 wt. % Fe, up to 0.50 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

[0189] Illustration 12 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises a ratio of a-phase and P-phase second phase particles (a-phase / P-phase) from 0.6 to 1.5.

[0190] Illustration 13 is the aluminum alloy of any preceding or subsequent illustration, wherein the ratio of a-phase / P-phase is from 0.7 to 1.1.

[0191] Illustration 14 is the aluminum alloy of any preceding or subsequent illustration, wherein a yield strength (Rp 0.2) of the aluminum alloy is from 80 MPa to 180 MPa when in a T4 temper, and wherein a tensile strength (Rm) of the aluminum alloy is from 200 MPa to 350 MPa when in a T4 temper.

[0192] Illustration 15 is the aluminum alloy of any preceding or subsequent illustration, wherein a yield strength (Rp 0.2) of the aluminum alloy is from 230 MPa to 320 MPa when in a T6 temper, and wherein a tensile strength (Rm) of the aluminum alloy is from 310 MPa to 370 MPa when in a T6 temper.

[0193] Illustration 16 is the aluminum alloy of any preceding or subsequent illustration, wherein a yield strength (Rp 0.2) of the aluminum alloy is from 230 MPa to 310 MPa when inAttorney Docket No. 108050-1527047 a T8x temper, and wherein a tensile strength (Rm) of the aluminum alloy is from 290 MPa to 360 MPa when in a T8x temper.

[0194] Illustration 17 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises a bending beta angle of 50° to 85° as measured according to VDA238-100 (2023) when in a T4 temper.

[0195] Illustration 18 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has an intergranular corrosion depth from 290 - 370 pm when in a T6 temper as measured according to ISO 11846B.

[0196] Illustration 19 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has an intergranular corrosion depth of less than 330 pm when in a T6 temper as measured according to ISO 11846B.

[0197] Illustration 20 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has an intergranular corrosion depth of 230 - 270 pm when in a T8x temper as measured according to ISO 11846B.

[0198] Illustration 21 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy is a 6xxx series aluminum alloy.

[0199] Illustration 22 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy is used to produce automotive parts for skin or structural applications.

[0200] Illustration 23 is a method of producing an aluminum alloy, comprising casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises 1.70 - 4.50 wt. % Si, 0.10 - 0.50 wt. % Fe, up to 0.40 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al, wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.5 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from up to 20 wt. % prime aluminum; homogenizing the cast product; hot rolling the cast product to produce a hot rolled product; cold rolling the rolled product to produce a final gauge rolled product; and solution heat treating the final gauge rolled product.

[0201] Illustration 24 is the method of any preceding or subsequent illustration, further comprising aging the final gauge rolled product to a T temper.

[0202] Illustration 25 is the method of any preceding or subsequent illustration, wherein the T temper is a T4 temper, a T6 temper, T8x, or a T82 temper.Attorney Docket No. 108050-1527047

[0203] Illustration 26 is the method of any preceding or subsequent illustration, further comprising pre-straining the final gauge rolled product.

[0204] Illustration 27 is the method of any preceding or subsequent illustration, wherein a ratio of end-of-life scrap to run-around scrap in the aluminum alloy is 1 : 1.

[0205] Illustration 28 is the method of any preceding or subsequent illustration, wherein the final gauge rolled product is a sheet.

[0206] Illustration 29 is the method of any preceding or subsequent illustration, further comprising joining the sheet to one or more additional alloy products by remote laser welding without filler wire.

[0207] Illustration 30 is the method of any preceding or subsequent illustration, wherein at least one of the one or more additional alloy products is an aluminum alloy sheet comprising the composition of Illustration 1.

[0208] Illustration 31 is a method for joining aluminum alloy products, the method comprising: providing a first aluminum alloy product comprising 1.70 - 4.50 wt. % Si, 0.10 - 0.50 wt. % Fe, up to 0.40 wt. % Mn, up to 0.60 wt. % Mg, up to 0.50 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al, wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.50 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from less than 20 wt. % prime aluminum; providing a second aluminum alloy product; joining the first aluminum alloy product to the second aluminum alloy product by remote laser welding without filler wire.

[0209] Illustration 32 is the method of any preceding or subsequent illustration, wherein the first aluminum alloy product is monolithic.

[0210] Illustration 33 is the method of any preceding or subsequent illustration, wherein the second aluminum alloy product is monolithic.

[0211] Illustration 34 is the method of any preceding or subsequent illustration, wherein the first aluminum alloy product is a rolled aluminum alloy sheet.

[0212] 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 be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

Attorney Docket No. 108050-1527047WHAT IS CLAIMED IS:

1. An aluminum alloy comprising:0.8 wt. % to 4.6 wt. % silicon,0.0 wt. % to 0.9 wt. % iron,0.05 wt. % to 1.2 wt. % copper,0.1 wt. % to 1.4 wt. % manganese,0.05 wt.% to 0.9 wt.% magnesium, up to 0.4 wt. % chromium, up to 1.00 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum; and wherein the aluminum alloy comprises a uniform elongation of greater than or about 15% in a T4 temper or an O temper or an under-solutionized condition.

2. The aluminum alloy of claim 1, wherein the aluminum alloy comprises at least 50 wt. % recycled content, and wherein at least 50 wt. % of the recycled content is brazing scrap.

3. The aluminum alloy of claim 1, wherein the aluminum alloy comprises at least 50 wt. % recycled content, and 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, end of life scrap, run around scrap, or a combination thereof.

4. The aluminum alloy of claim 2, wherein the aluminum alloy comprises at least 70 wt. % recycled material, and wherein at least 55 wt. % of the recycled material is a mixed cladded alloy recycled material.

5. The aluminum alloy of claim 1 comprising:0.9 wt. % to 2.7 wt. % silicon,0.0 wt. % to 0.8 wt. % iron,0.07 wt. % to 0.9 wt. % copper,0.5 wt. % to 1.3 wt. % manganese,Attorney Docket No. 108050-15270470.07 wt.% to 0.9 wt.% magnesium, up to 0.3 wt. % chromium, up to 0.3 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum.

6. The aluminum alloy of claim 1, wherein the aluminum alloy comprises a yield strength of greater than or about 120 MPa in a T4 temper, a yield strength of greater than or about 250 MPa in a T6 temper, a yield strength of less than or about 80 MPa in an O temper or an under- solutionized condition, or a yield strength of greater than or about 220 MPa in a T8 temper.

7. An aluminum alloy, comprising1.70 - 4.60 wt. % Si,0.10 - 0.70 wt. % Fe, up to 0.60 wt. % Mn, up to 0.90 wt. % Mg, up to 1.20 wt. % Cu, up to 0.30 wt. % Cr, up to 1.00 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al; wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.50 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from less than 20 wt. % prime aluminum.

8. The aluminum alloy of claim 7, wherein the aluminum alloy comprises1.70 - 4.50 wt. % Si,0.40 - 0.60 wt. % Fe, up to 0.60 wt. % Mn,0.60 - 0.90 wt. % Mg,0.75 - 1.20 wt. % Cu,Attorney Docket No. 108050-1527047 up to 0.30 wt. % Cr,0.40 - 0.60 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

9. The aluminum alloy of claim 7, wherein the aluminum alloy comprises1.70 - 4.50 wt. % Si,0.40 - 0.60 wt. % Fe, up to 0.60 wt. % Mn, up to 0.90 wt. % Mg, up to 1.20 wt. % Cu, up to 0.30 wt. % Cr, up to 0.60 wt. % Zn, up to 0.25 wt. % of impurities, and remainder Al.

10. The aluminum alloy of claim 7, wherein the aluminum alloy comprises a ratio of a- phase and P-phase second phase particles (a-phase / P-phase) from 0.6 to 1.5.

11. The aluminum alloy of claim 7, wherein a yield strength (Rp 0.2) of the aluminum alloy is from 80 MPa to 180 MPa when in a T4 temper, from 230 MPa to 320 MPa when in a T6 temper, or from 230 MPa to 310 MPa when in a T8x temper.

12. The aluminum alloy of claim 7, wherein a tensile strength (Rm) of the aluminum alloy is from 200 MPa to 350 MPa when in a T4 temper, from 310 MPa to 370 MPa when in a T6 temper, from 290 MPa to 360 MPa when in a T8x temper.

13. The aluminum alloy of claim 7, wherein the aluminum alloy has an intergranular corrosion depth from 290 - 370 pm when in a T6 temper, less than 330 pm when in a T6 temper, or 230 - 270 pm when in a T8 temper, as measured according to ISO 11846B,14. A method of producing an aluminum alloy comprising:Attorney Docket No. 108050-1527047 casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises0.8 wt. % to 4.6 wt. % silicon,0.0 wt. % to 0.9 wt. % iron,0.05 wt. % to 1.2 wt. % copper,0.1 wt. % to 1.4 wt. % manganese,0.05 wt.% to 0.9 wt.% magnesium, up to 0.4 wt. % chromium, up to 1.0 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum, optionally homogenizing and / or pre-heating the cast product; hot rolling the optionally homogenized and / or pre-heated product to produce a hot rolled product; optionally cold rolling the hot rolled product and optionally inter-annealing to produce a cold rolled product; solution heat treating or annealing the rolled product at a final gauge, optionally pre-ageing the solution heat treated product, and optionally artificial aging of the solution heat treated product or the pre-aged product.

15. The method of claim 14, further comprising aging the final gauge rolled product to a T temper, an O temper or an under-solutionized condition.

16. The method of claim 14, wherein the cast product is cast from an aluminum alloy comprising one or more of a cladded 3xxx series aluminum alloy, an uncladded 3xxx series aluminum alloy, a cladded 6xxx series aluminum alloy, an uncladded 6xxx series aluminum alloy, end of life scrap, run around scrap, or a combination thereof.

17. The method of claim 14, wherein the cast product is cast from an aluminum alloy comprising at least 70 wt. % recycled material.Attorney Docket No. 108050-152704718. The method of claim 14, wherein the cast product is cast from an aluminum alloy comprising less than 20 wt. % prime aluminum.

19. A product fabricated with the aluminum alloy of claims 1 or 7, or as formed according to the method of claim 14, wherein the product comprises a structural automotive part or an automotive skin.

20. A method for joining aluminum alloy products, the method comprising: providing a first aluminum alloy product comprising:0.8 wt. % to 4.6 wt. % silicon,0.0 wt. % to 0.9 wt. % iron,0.05 wt. % to 1.2 wt. % copper,0.1 wt. % to 1.4 wt. % manganese,0.05 wt.% to 0.9 wt.% magnesium, up to 0.4 wt. % chromium, up to 1.0 wt. % zinc, up to 0.4 wt. % titanium, up to 0.3 wt. % of impurities, and aluminum, wherein the aluminum alloy is produced from 80 wt. % or more of recycled aluminum alloy scrap comprising end of life scrap comprising at least 4 wt. % Si, run-around scrap comprising at least 0.50 wt. % Si, or combinations thereof; and wherein the aluminum alloy is produced from less than 20 wt. % prime aluminum; providing a second aluminum alloy product; joining the first aluminum alloy product to the second aluminum alloy product by remote laser welding without filler wire.

21. The method of claim 20, wherein the first aluminum alloy product, the second aluminum alloy product, or both the first and second aluminum alloy products are monolithic.

22. The method of claim 20, wherein the first aluminum alloy product is a rolled aluminum alloy sheet.

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