Clad aluminum alloy products for aerospace applications and related processes

Abstract

Clad aluminum alloy products can include a core layer comprising an AA2xxx series aluminum alloy and cladding layer comprising an AA2xxx series aluminum alloy. The chemistry of each of the AA2xxx series aluminum alloys, especially the Cu content and the Mg content, can be tailored to improve corrosion resistance. Such clad aluminum alloy products may be suitable for structural aerospace parts including use in hydrogen tank applications.

Description

Attorney Docket No. 108050-1530025CLAD ALUMINUM ALLOY PRODUCTS FOR AEROSPACE APPLICATIONS AND RELATED PROCESSESCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 714,185, filed October 31, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes.FIELD

[0002] Described herein are clad aluminum alloy products comprising an AA2xxx series aluminum alloy core layer and an AA2xxx series aluminum alloy cladding layer coupled to at least one surface of the core layer. The clad aluminum alloy products may be suitable for structural aerospace parts including use in hydrogen tank application.BACKGROUND

[0003] In the aerospace industry, the AA2024 series aluminum alloy, the AA2219 series aluminum alloy, and modifications thereof are widely used as a high damage-tolerant aluminum alloys, mostly with a T3, O, and F temper or modifications thereof. Products of these aluminum alloys have a relatively high strength-to-weight ratio and exhibit good fracture toughness, good fatigue properties, and adequate corrosion resistance.

[0004] To enhance the corrosion resistance, the AA2024 series aluminum alloy product may be provided as a composite product with a cladding layer on one or both sides of the AA2024 series alloy product. For corrosion protection, cladding layers with higher purity aluminum (e.g., greater than 99.5% aluminum) have been generally preferred. However, higher purity aluminum is very soft and sensitive to surface damage during handling of the product.SUMMARY

[0005] 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. TheAttorney Docket No. 108050-1530025 subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings and each claim.

[0006] Described herein are clad aluminum alloy products comprising: a core layer having a first surface and a second surface on opposing sides of the core layer comprising a first aluminum alloy; and a cladding layer at one or both of the first surface and the second surface, wherein the cladding layer comprises a second aluminum alloy.

[0007] The first aluminum alloy can, for example, comprise up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum. The first aluminum alloy can, for example, comprise up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0008] The second aluminum alloy can, for example, comprise up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum. The second aluminum alloy can, for example, comprise up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0009] In some aspects, a Cu content in the core layer can be at least 3 wt. % greater than a Cu content in the cladding layer.

[0010] In some aspects, a corrosion potential of the core layer can be at least 50 mV greater than a corrosion potential of the cladding layer. In some aspects, a corrosion potential of the core layer can be at least 40 mV greater than a corrosion potential of the cladding layer.

[0011] In some aspects, the cladding layer can have a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

[0012] Described herein are processes for producing a clad aluminum alloy product comprising a core layer and a cladding layer. The process can comprise co-casting an ingot having a core and a cladding on at least one outer surface of the core; and processing the ingot to form the clad aluminum alloy product. The core layer comprises a first aluminum alloy; and the cladding layer comprises a second aluminum alloy.Attorney Docket No. 108050-1530025

[0013] The first aluminum alloy can, for example, comprise up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum. The first aluminum alloy can, for example, comprise up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0014] The second aluminum alloy can, for example, comprise up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum. The second aluminum alloy can, for example, comprise up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0015] The solutionizing step can have a peak metal temperature of about 450 °C to about 545 °C. Further, the tempering step can result in a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

[0016] Described herein are processes for producing a clad aluminum alloy product comprising a core layer and a cladding layer. The process can comprise joining the core layer and the cladding layer such that the cladding layer is bonded to at least one surface of the core layer. The core layer comprises a first aluminum alloy; and the cladding layer comprises a second aluminum alloy.

[0017] The first aluminum alloy can, for example, comprise up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum. The first aluminum alloy can, for example, comprise up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0018] The second aluminum alloy can, for example, comprise up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum. The second aluminum alloy can, for example, comprise up toAttorney Docket No. 108050-15300250.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0019] In some aspects, a corrosion potential of the core layer can be at least 50 mV greater than a corrosion potential of the cladding layer. In some aspects, a corrosion potential of the core layer can be at least 40 mV greater than a corrosion potential of the cladding layer

[0020] In some aspects, the clad cladding layer can have a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

[0021] Described herein are products fabricated with any of the foregoing clad aluminum alloy products or fabricated with a clad aluminum alloy product. The clad aluminum alloy product can be a clad aluminum alloy product according to any of the compositions or produced according to any of the foregoing processes. The product can, for example, be a hydrogen tank or portion thereof.

[0022] Described herein are processes comprising assembling and securing via welding a clad aluminum alloy product to a metal product. The clad aluminum alloy product can be a clad aluminum alloy product according to any of the compositions or produced according to any of the foregoing processes.

[0023] Further aspects, obj ects, and advantages of the invention will become apparent upon consideration of the detailed description that follows.DETAILED DESCRIPTION OF THE INVENTION

[0024] The disclosure is directed to clad aluminum alloy products that include a core layer comprising an AA2xxx series aluminum alloy and cladding layer comprising an AA2xxx series aluminum alloy. Advantageously, the chemistry of each of the AA2xxx series aluminum alloys described herein is tailored to improve corrosion resistance while having a structurally robust cladding layer with good weldability.Definitions and Descriptions

[0025] 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.Attorney Docket No. 108050-1530025

[0026] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0027] As used herein, the meaning of “metals” includes pure metals, alloys and metal solid solutions unless the context clearly dictates otherwise.

[0028] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “2xxx” or “AA2xxx.” 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.

[0029] 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.

[0030] 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.

[0031] As used herein, a sheet generally refers to an aluminum alloy product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm.

[0032] Reference is made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.”

[0033] 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.

[0034] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.Attorney Docket No. 108050-1530025

[0035] 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.

[0036] 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%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.

[0037] 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 thatAttorney Docket No. 108050-1530025 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

[0038] Core Layer

[0039] Aluminum alloys suitable for use in the core layer of the compositions, products, and processes described herein can, for example, have the following elemental composition as provided in Table 1.Table 1

[0040] In some examples, the aluminum alloy for optional use as a core layer can have the following elemental composition as provided in Table 2.Table 2Attorney Docket No. 108050-1530025

[0041] In some examples, the aluminum alloy for optional use as a core layer can have the following elemental composition as provided in Table 3.Table 3

[0042] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 1-3, the predominant element is aluminum (Al), sometimes called “remainder Al.” In other words, the term “remainder” can be used to describe predominant aluminum (Al) content in the aluminum alloys described herein.

[0043] In certain examples, the disclosed aluminum alloy used in the core layer includes silicon (Si) in an amount up to about 1.2 % (e.g., from 0 % to 1.2 %, from 0.05 % to 1.2 %,Attorney Docket No. 108050-1530025 from 0 % to 0.7 %, from 0.05 % to 0.7 %, from 0 % to 0.4 %, or from 0.05 % to 0.4 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, or 1.20 % Si. In some cases, the disclosed alloy does not include Si (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0044] In certain examples, the disclosed aluminum alloy used in the core layer includes iron (Fe) in an amount up to about 1.3 % (e.g., from 0 % to 1.3 %, from 0.05 % to 1.3 %, from 0 % to 1.0 %, from 0.05 % to 1.0 %, from 0 % to 0.7 %, from 0.05 % to 0.7 %, from 0 % to 0.4 %, from 0.05 % to 0.4 %, from 0.05 % to 0.3 %, from 0.05 % to 0.2 %, or from 0.05 % to 0.1 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %,0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, or 1.30 % Fe. 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.

[0045] In certain examples, the disclosed aluminum alloy used in the core layer includes copper (Cu) in an amount from about 1.9 % to about 9 % (e.g., from 1.9 % to 8 %, from 3 % to 8 %, from 4 % to 8 %, from 4.5 % to 7.5 %, from 5.5 % to 7.5 %, or from 6 % to 7 %) based on the total weight of the alloy. For example, the alloy can include 1.90 %, 1.95 %, 2.00 %, 2.05 %, 2.10 %, 2.15 %, 2.20 %, 2.25 %, 2.30 %, 2.35 %, 2.40 %, 2.45 %, 2.50 %, 2.55 %, 2.60 %, 2.65 %, 2.70 %, 2.75 %, 2.80 %, 2.85 %, 2.90 %, 2.95 %, 3.00 %, 3.05 %, 3.10 %,3.15 %, 3.20 %, 3.25 %, 3.30 %, 3.35 %, 3.40 %, 3.45 %, 3.50 %, 3.55 %, 3.60 %, 3.65 %,3.70 %, 3.75 %, 3.80 %, 3.85 %, 3.90 %, 3.95 %, 4.00 %, 4.05 %, 4.10 %, 4.15 %, 4.20 %,4.25 %, 4.30 %, 4.35 %, 4.40 %, 4.45 %, 4.50 %, 4.55 %, 4.60 %, 4.65 %, 4.70 %, 4.75 %,4.80 %, 4.85 %, 4.90 %, 4.95 %, 5.00 %, 5.05 %, 5.10 %, 5.15 %, 5.20 %, 5.25 %, 5.30 %5.35 %, 5.40 %, 5.45 %, 5.50 %, 5.55 %, 5.60 %, 5.65 %, 5.70 %, 5.75 %, 5.80 %, 5.85 %,5.90 %, 5.95 %, 6.00 %, 6.05 %, 6.10 %, 6.15 %, 6.20 %, 6.25 %, 6.30 %, 6.35 %, 6.40 %,6.45 %, 6.50 %, 6.55 %, 6.60 %, 6.65 %, 6.70 %, 6.75 %, 6.80 %, 6.85 %, 6.90 %, 6.95 %,7.00 %, 7.05 %, 7.10 %, 7.15 %, 7.20 %, 7.25 %, 7.30 %, 7.35 %, 7.40 %, 7.45 %, 7.50 %,7.55 %, 7.60 %, 7.65 %, 7.70 %, 7.75 %, 7.80 %, 7.85 %, 7.90 %, 7.95 %, 8.00 %, 8.05 %,8.10 %, 8.15 %, 8.20 %, 8.25 %, 8.30 %, 8.35 %, 8.40 %, 8.45 %, 8.50 %, 8.55 %, 8.60 %,8.65 %, 8.70 %, 8.75 %, 8.80 %, 8.85 %, 8.90 %, 8.95 %, or 9.00 % Cu. All expressed in wt.% based on the total weight of the aluminum alloy.Attorney Docket No. 108050-1530025

[0046] In certain examples, the disclosed aluminum alloy used in the core layer includes manganese (Mn) in an amount up to about 1.2 % (e.g., from 0 % to 1.2 %, from 0.05 % to 1.2 %, from 0.1 % to 1.2 %, from 0 % to 1%, from 0.05 % to 1 %, from 0.1 % to 1 %, from 0 % to 0.75 %, from 0.05 % to 0.75 %, or from 0.1 % to 0.75 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, or 1.20 % Mn. In some cases, the disclosed alloy does not include Mn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0047] In certain examples, the disclosed aluminum alloy used in the core layer includes magnesium (Mg) in an amount up to about 1.8 % (e.g., from 0 % to 1.8 %, from 0.01 % to 1.8 %, from 0.05 % to 1.8 %, from 0 % to 1 %, from 0.05 % to 1 %, from 0.1 % to 1 %, from 0 % to 0.25 %, from 0.05 % to 0.25 %, from 0 % to 0.1 %, or from 0.05 % to 0.1 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %,0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %,0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %,1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, or 1.80 % Mg. In some cases, the disclosed alloy does not include Mg (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0048] In certain examples, the disclosed aluminum alloy used in the core layer includes nickel (Ni) in an amount up to about 1.5 % (e.g., from 0 % to 1.5 %, from 0.05 % to 1.5 %, from 0 % to 1 %, from 0.05 % to 1 %, from 0 % to 0.5 %, from 0.05 % to 0.5 %, from 0 % to 0.25 %, from 0.05 % to 0.25 %, from 0 % to 0.1 %, or from 0.05 % to 0.1 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, or 1.50 % Ni. In some cases, the disclosed alloy does not include Ni (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0049] In certain aspects, the disclosed aluminum alloy used in the core layer includes chromium (Cr) in an amount up to about 0.1 % (e.g., from 0 % to 0.1 %, from 0.01 % to 0.1 %, from 0 % to 0.05 %, or from 0.01 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090Attorney Docket No. 108050-1530025%, 0.095 %, or 0.100 % 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.

[0050] In certain examples, the disclosed aluminum alloy used in the core layer includes zinc (Zn) in an amount up to about 0.25 % (e.g., from 0 % to 0.25 %, from 0.001 % to 0.25 %, from 0 % to 0.15 %, from 0.001 % to 0.15 %, from 0 % to 0.1 %, or from 0.001 % to 0.1 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, or 0.250 % 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.

[0051] In certain aspects, the disclosed aluminum alloy used in the core layer includes titanium (Ti) in an amount up to about 0.15 % (e.g., from 0 % to 0.15 %, from 0.001 % to 0.15 %, from 0 % to 0.1 %, or from 0.001 % to 0.1 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, or 0.150 % 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.

[0052] In certain aspects, the disclosed aluminum alloy used in the core layer includes zirconium (Zr) in an amount up to about 0.3 % (e.g., from 0 % to 0.30 %, from 0.05 % to 0.30 %, from 0.10 % to 0.30 %, from 0 % to 0.25 %, from 0.05 % to 0.25 %, from 0.10 % to 0.25 %, from 0.05 % to 0.20 %, or from 0.05 % to 0.15 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080%, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130%, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230%, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280%, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Zr. In some cases, the disclosed alloy does not include Zr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.Attorney Docket No. 108050-1530025

[0053] In certain aspects, the disclosed aluminum alloy used in the core layer includes vanadium (V) in an amount up to about 0.2 % (e.g., from 0 % to 0.2 %, from 0.001 % to 0.2 %, from 0.001 % to 0.15 %, from 0.001 % to 0.1 %, from 0.001 % to 0.05 %, or from 0.001 % to 0.01 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, or 0.200 % V. In some cases, the disclosed alloy does not include V (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0054] Optionally, the alloy can further include other minor elements, sometimes referred to as impurities, in amounts of about 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), yttrium (Y), hafnium (Hf), thallium (Th), gallium (Ga), tin (Sn), lead (Pb), silver (Ag), bismuth (Bi), strontium (Sr), calcium (Ca), lithium (Li), or combinations thereof. Accordingly, Sc, Y, Hf, Th, Ga, Sn, Pb, Ag, Bi, Sr, Ca, or Li, if present, may each independently be present in an alloy in amounts of 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 0.15 % (e.g., does not exceed 0.10 %, or does not exceed 0.05 %). In certain aspect, the apply compositions may be devoid of (not comprise or comprise at 0.00 %) one or more of: Sc, Y, Hf, Th, Ga, Sn, Pb, Ag, Bi, Sr, Ca, and Li. All expressed in wt. % based on the total weight of the aluminum alloy.

[0055] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder Al.

[0056] Regarding the composition of the core layer, any alloy designated as an AA2xxx series aluminum alloy including modified versions thereof to achieve the desired chemical composition is suitable for use as the core layer. Preferably, the core layer is an AA2219 series aluminum alloy or modification thereof.

[0057] Cladding Layer

[0058] Aluminum alloys suitable for use in the cladding layer of the compositions, products, and processes described herein can, for example, have the following elemental composition as provided in Table 4.Attorney Docket No. 108050-1530025Table 4

[0059] In some examples, the aluminum alloy for optional use as a cladding layer can have the following elemental composition as provided in Table 5.Table 5Attorney Docket No. 108050-1530025

[0060] In some examples, the aluminum alloy for optional use as a cladding layer can have the following elemental composition as provided in Table 6.Table 6

[0061] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 4-6, the predominant element is 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.

[0062] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Si in an amount up to about 0.5 % (e.g., from 0 % to 0.5 %, from 0.05 % to 0.5 %, from 0 % to 0.4 %, from 0.05 % to 0.4 %, from 0 % to 0.3 %, or from 0.05 % to 0.3 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160%, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210%, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260%, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, 0.300 %, 0.305 %, 0.310%, 0.315 %, 0.320 %, 0.325 %, 0.330 %, 0.335 %, 0.340 %, 0.345 %, 0.350 %, 0.355 %, 0.360%, 0.365 %, 0.370 %, 0.375 %, 0.380 %, 0.385 %, 0.390 %, 0.395 %, 0.400 %, 0.405 %, 0.410%, 0.415 %, 0.420 %, 0.425 %, 0.430 %, 0.435 %, 0.440 %, 0.445 %, 0.450 %, 0.455 %, 0.460Attorney Docket No. 108050-1530025%, 0.465 %, 0.470 %, 0.475 %, 0.480 %, 0.485 %, 0.490 %, 0.495 %, or 0.500 % Si. In some cases, the disclosed alloy does not include Si (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0063] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Fe in an amount up to about 0.4 % (e.g., from 0 % to 0.4 %, from 0.05 % to 0.4 %, from 0 % to 0.3 %, or from 0.05 % to 0.3 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135%, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185%, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235%, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285%, 0.290 %, 0.295 %, 0.300 %, 0.305 %, 0.310 %, 0.315 %, 0.320 %, 0.325 %, 0.330 %, 0.335%, 0.340 %, 0.345 %, 0.350 %, 0.355 %, 0.360 %, 0.365 %, 0.370 %, 0.375 %, 0.380 %, 0.385%, 0.390 %, 0.395 %, or 0.400 % Fe. 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.

[0064] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Cu in an amount from about 0.5 % to about 2.8 % (e.g., from 0.5 % to 2.6 %, from 0.5 % to 2.4 %, from 0.5 % to 2.2 %, from 0.5 % to 2 %, from 0.5 % to 1.8 %, from 0.5 % to 1.6 %) based on the total weight of the alloy. For example, the alloy can include 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05 %,1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %,1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95 %, 2.00 %, 2.05 %, 2.10 %, 2.15 %,2.20 %, 2.25 %, 2.30 %, 2.35 %, 2.40 %, 2.45 %, 2.50 %, 2.55 %, 2.60 %, 2.65 %, 2.70 %,2.75 %, 2.80 % Cu. All expressed in wt. % based on the total weight of the aluminum alloy.

[0065] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Mn in an amount up to about 0.5 % (e.g., from 0 % to 0.5 %, from 0.05 % to 0.5 %, from 0 % to 0.4 %, from 0.05 % to 0.4 %, from 0 % to 0.3 %, or from 0.05 % to 0.3 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110%, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160%, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210%, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260%, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, 0.300 %, 0.305 %, 0.310Attorney Docket No. 108050-1530025%, 0.315 %, 0.320 %, 0.325 %, 0.330 %, 0.335 %, 0.340 %, 0.345 %, 0.350 %, 0.355 %, 0.360%, 0.365 %, 0.370 %, 0.375 %, 0.380 %, 0.385 %, 0.390 %, 0.395 %, 0.400 %, 0.405 %, 0.410%, 0.415 %, 0.420 %, 0.425 %, 0.430 %, 0.435 %, 0.440 %, 0.445 %, 0.450 %, 0.455 %, 0.460%, 0.465 %, 0.470 %, 0.475 %, 0.480 %, 0.485 %, 0.490 %, 0.495 %, or 0.500 % Mn. In some cases, the disclosed alloy does not include Mn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0066] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Mg in an amount up to about 1 % (e.g., from 0 % to 1 %, from 0.01 % to 1 %, from 0 % to 0.8 %, from 0.01 % to 0.8 %, from 0 % to 0.7 %, or from 0.01 % to 0.7 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.05 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95%, or 1.00 % Mg. In some cases, the disclosed alloy does not include Mg (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0067] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes Cr in an amount up to about 0.25 % (e.g., from 0 % to 0.25 %, from 0.05 % to 0.25 %, from 0 % to 0.15 %, or from 0.05 % to 0.15 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085%, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135%, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185%, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235%, 0.240 %, 0.245 %, or 0.250 % 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.

[0068] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Zn in an amount up to about 0.3 % (e.g., from 0 % to 0.3 %, from 0.05 % to 0.3 %, from 0 % to 0.2 %, or from 0.05 % to 0.2 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135%, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185%, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235%, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285%, 0.290 %, 0.295 %, or 0.300 % 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.Attorney Docket No. 108050-1530025

[0069] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes Ti in an amount up to about 0.2 % (e.g., from 0 % to 0.2 %, from 0.01 % to 0.2 %, from 0.01 % to 0.1 %, or from 0.05 % to 0.15 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, or 0.200 % 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.

[0070] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes Zr in an amount up to about 0.3 % (e.g., from 0 % to 0.3 %, from 0.05 % to 0.3 %, from 0 % to 0.2 %, or from 0.05 % to 0.2 %) based on the total weight of the alloy. For example, the alloy can include 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185%, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235%, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285%, 0.290 %, 0.295 %, or 0.300 % Zr. In some cases, the disclosed alloy does not include Zr(i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0071] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes V in an amount up to about 0.3 % (e.g., from 0 % to 0.3 %, from 0.001 % to 0.3 %, from 0.001 % to 0.25 %, from 0.001 % to 0.2 %, from 0.001 % to 0.15 %, from 0.001 % to 0.1 %, from 0.001 % to 0.05 %, or from 0.001 % to 0.01 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125%, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175%, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225%, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275%, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % V. In some cases, the disclosed alloy does not include V (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.Attorney Docket No. 108050-1530025

[0072] Optionally, the disclosed aluminum alloy used in the cladding layer can further include other minor elements, sometimes referred to as impurities, in amounts of about 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, Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Ag, Bi, Sr, Ca, Li, or combinations thereof. Accordingly, Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Ag, Bi, Sr, Ca, or Li, if present, may each independently be present in an alloy in amounts of 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 0.15 % (e.g., does not exceed 0.10 %, or does not exceed 0.05 %). In certain aspect, the apply compositions may be devoid of (not comprise or comprise at 0.00 %) one or more of: Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Ag, Bi, Sr, Ca, and Li. All expressed in wt. % based on the total weight of the aluminum alloy.

[0073] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder Al.Production Processes and Properties of Clad Aluminum Alloy Products

[0074] The alloys described herein for use as the core layer and cladding layer can be cast using any suitable casting method. As a few non-limiting examples, the casting process can include a direct chill (DC) casting process or a continuous casting (CC) process.

[0075] A cladding layer as described herein can be attached to a core layer as described herein to form a clad product by any means known to persons of ordinary skill in the art. For example, a cladding layer can be attached to a core layer by direct chill co-casting (i.e., fusion casting) as described in, for example, U.S. Pat. Nos. 7,748,434 and 8,927,113, both of which are hereby incorporated by reference in their entireties; by hot and cold rolling a composite cast ingot as described in U.S. Pat. No. 7,472,740, which is hereby incorporated by reference in its entirety; or by roll bonding to achieve the required metallurgical bonding between the core layer and the cladding layer; or by other methods as known to persons of ordinary skill in the art. The initial dimensions and final dimensions of the clad aluminum alloy products described herein can be determined by the desired properties of the overall final product.

[0076] The roll bonding process can be carried out in different manners, as known to those of ordinary skill in the art. For example, the roll-bonding process can include both hot rolling and cold rolling. Further, the roll bonding process can be a one-step process or a multi-step process in which the material is gauged down during successive rolling steps. Separate rollingAttorney Docket No. 108050-1530025 steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, and the like.

[0077] The co-cast ingot or other cast product can be processed by any means known to those of ordinary skill in the art. Optionally, the processing steps can be used to prepare sheets. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and an optional pre-aging step, as known to those of ordinary skill in the art.

[0078] In the homogenization step of a DC casting process, the co-cast ingot described herein is heated to a temperature ranging from about 400 °C to about 545 °C (e.g., from about 410 °C to about 525 °C, from about 415 °C to about 515 °C, or from about 425 °C to about 500 °C). For example, the ingot can be heated to a temperature of about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 505 °C, about 510 °C, about 515 °C, about 520 °C, about 525 °C, about 530 °C, or about 535 °C. The ingot is then allowed to soak (i.e., held at the indicated temperature) for a period of time. In some examples, the total time for the homogenization step, including the heating and soaking phases, can be up to 30 hours. For example, the ingot can be heated up to 525 °C and soaked, for a total time of up to 30 hours for the homogenization step. For example, the ingot can be heated up to 500 °C and soaked, for a total time of up to 18 hours for the homogenization step. Optionally, the ingot can be heated to below 490 °C and soaked, for a total time of greater than 18 hours for the homogenization step. In some cases, the homogenization step comprises multiple processes. In some non-limiting examples, the homogenization step includes heating the ingot to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, the ingot can be heated to about 465 °C for about 3.5 hours and then heated to about 480 °C for about 6 hours.

[0079] Following the homogenization step of the co-cast ingot, a hot rolling step can be performed. Prior to the start of hot rolling, the homogenized ingot can be allowed to cool to a temperature of from about 300 °C to about 470 °C (from about 315 °C to about 450 °C, from about 325 °C to about 425 °C, from about 340 °C to about 400 °C, or from about 350 °C to about 400 °C). In some examples, the homogenized ingot can be allowed to cool to a temperature of from about 325 °C to about 425 °C or from about 350 °C to about 400 °C. The ingots can then be hot rolled at a temperature between 300 °C to 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge of from about 3 mm to about 200Attorney Docket No. 108050-1530025 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature of from about 300 °C to about 450 °C. For example, the continuously cast product can be allowed to cool to a temperature of from about 325 °C to about 425 °C or from about 350 °C to about 400 °C. The continuously cast product can then be hot rolled at a temperature of from about 300 °C to about 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge of from about 3 mm to about 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the clad aluminum alloy hot rolled product upon exit from the hot rolling mill is no more than about 470 °C, no more than about 450 °C, no more than about 440 °C, or no more than about 430 °C.

[0080] The clad plate, shate, or sheet can then be cold rolled using conventional cold rolling mills and technology. The cold rolled clad sheet can have a gauge of from about 0.5 mm to about 10 mm, e.g., between about 0.7 mm to about 6.5 mm. Optionally, the cold rolled clad sheet 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 about 85% (e.g., up to about 10%, up to about 20%, up to about 30%, up to about 40%, up to about 50%, up to about 60%, up to about 70%, up to about 80%, or up to about 85% reduction). The thickness of a single cladding layer may be between about 2% and about 10% (e.g., about 2% to about 4%, about 3% to about 5%, about 4% to about 6%, about 5% to about 7%, about 6% to about 8%, about 7% to about 9%, or about 8% to about 10%) of the total thickness of the cold rolled clad sheet. Optionally, an interannealing step can be performed during the cold rolling step. The interannealing step can be performed at a temperature of from about 300 °C to about 470 °C (e.g., from about 315 °C to about 450 °C, from about 325 °C to about 425 °C, from about 340 °C to about 400 °C, or from about 350 °C to about 400 °C). For example, the interannealing step can be performed atAttorney Docket No. 108050-1530025 a temperature of about 300 °C, about 310 °C, about 320 °C, about 330 °C, about 340 °C, about 350 °C, about 360 °C, about 370 °C, about 380 °C, about 390 °C, about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, or about 470 °C. In some cases, the interannealing step includes multiple processes. In some non-limiting examples, the interannealing step includes heating the clad plate, shate, or sheet to a first temperature (e.g., about 380 °C to about 440 °C, about 380 °C, about 390 °C, about 400 °C, about 410 °C, about 420 °C, about 430 °C, or about 440 °C) for a first period of time (e.g., about 15 minutes to about 4 hours, about 15 minutes, about 30 minutes, about 1 hour, about 2 hours, about 3 hours, or about 4 hours) followed by heating to a second temperature (e.g., about 300 °C to about 360 °C, about 300 °C, about 310 °C, about 320 °C, about 330 °C, about 340 °C, about 350 °C, or about 360 °C) for a second period of time (e.g., about 30 minutes to about 6 hours, about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours). For example, the clad plate, shate, or sheet can be heated to about 410 °C for about 1 hour and then heated to about 330 °C for about 2 hours.

[0081] Subsequently, the clad plate, shate, or sheet can undergo a solution heat treatment step. The solution heat treatment step can include any conventional treatment for the clad sheet which results in solutionizing of the soluble particles. The clad plate, shate, or sheet can be heated to a peak metal temperature (PMT) of up to about 545 °C (e.g., from about 450 °C to about 545 °C) and soaked for a period of time at the temperature. For example, the clad plate, shate or sheet can be soaked at about 480 °C for a soak time of up to about 60 minutes (e.g., 0 seconds, about 60 seconds, about 75 seconds, about 90 seconds, about 5 minutes, about 10 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 40 minutes, about 50 minutes, or about 60 minutes). After heating and soaking, the clad plate, shate, or sheet is rapidly cooled at rates greater than 50 °C / second (°C / s) to a temperature from about 545 °C to about 200 °C. In one example, the clad plate, shate or sheet has a quench rate of above 200 °C / s at temperatures from about 450 °C to about 200 °C. Optionally, the cooling rates can be faster in other cases. For thicker gauges, the cooling rate may be slower, for example, about 1 °C / second to about 10 °C / second.

[0082] In the clad aluminum alloy product, a Cu content of the core layer may be at least 3 wt. % (e.g., 3 wt. % to 7 wt. %, 4 wt. % to 7 wt. %, or 5 wt. % to 7 wt. %) greater than a Cu content in the cladding layer. For example, a core layer with a Cu content of 6.5 wt. % has a Cu content that is 5 wt. % greater than a cladding layer with a Cu content of 1.5 wt. %.Attorney Docket No. 108050-1530025

[0083] The open circuit potential corrosion (or corrosion potential) can be measured using ASTM G69-20. In the clad aluminum alloy product, the difference in corrosion potential between the core layer and the cladding layer may be at least 40 mV.Uses and Applications

[0084] Uses and applications of the clad aluminum alloy products described herein are included within the scope of the present disclosure, as are products, forms, apparatuses, and similar things fabricated with or comprising the aluminum alloys described herein. The processes for fabricating, producing, or manufacturing such products, forms, apparatuses, and similar things are also included within the scope of the present disclosure.

[0085] The clad aluminum alloy products described herein may be used in the construction of an aircraft or spacecraft including airplanes, unmanned aircraft, space shuttles, rockets, rotary wing aircrafts, and the like. The clad aluminum alloy products described herein may be at least a portion of a hydrogen fuel tank (also referred to herein as hydrogen tank), a wing assembly, a tail assembly, a fuselage, and the like.

[0086] The clad aluminum alloy products described herein may be formed into a desired structural shape where welding is used to create joints. For example, the process may include assembling and securing the clad aluminum alloy product of the present disclosure to a metal product (e.g., via welding to form a joint therebetween). The joint may be a seam where the clad aluminum alloy product is joined to itself. The joint may be between clad aluminum alloy product and another aluminum alloy product, which may or may not be a clad aluminum alloy product. The joint may be between clad aluminum alloy product and product having a composition other than aluminum alloy, for example, steel.

[0087] For example, clad aluminum alloy products described herein may be formed into welded fuselage structures where the fuselage panels are joined to each other using laser beam welding (“LBW”) or friction stir welding (“FSW”), for example, using butt welds.ILLUSTRATIVE ASPECTS

[0088] 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”).

[0089] Aspect 1. A clad aluminum alloy product comprising: a core layer having a first surface and a second surface on opposing sides of the core layer, wherein the core layerAttorney Docket No. 108050-1530025 comprises a first aluminum alloy that comprises up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum; and a cladding layer at one or both of the first surface and the second surface, wherein the cladding layer comprises a second aluminum alloy that comprises up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0090] Aspect 2. The clad aluminum alloy product of any previous or subsequent aspect, wherein a Cu content in the core layer is at least 3 wt. % greater than a Cu content in the cladding layer.

[0091] Aspect 3. The clad aluminum alloy product of any previous or subsequent aspect, wherein a corrosion potential of the core layer is at least 50 mV greater than a corrosion potential of the cladding layer.

[0092] Aspect 4. The clad aluminum alloy product of any previous or subsequent aspect, wherein a corrosion potential of the core layer is at least 40 mV greater than a corrosion potential of the cladding layer.

[0093] Aspect 5. The clad aluminum alloy product of any previous or subsequent aspect, wherein the cladding layer has a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

[0094] Aspect 6. The clad aluminum alloy product of any previous or subsequent aspect, wherein the first aluminum alloy comprises up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0095] Aspect 7. The clad aluminum alloy product of any previous or subsequent aspect, wherein the second aluminum alloy comprises up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0096] Aspect 8. A product fabricated with the clad aluminum alloy product of any previous or subsequent aspect.Attorney Docket No. 108050-1530025

[0097] Aspect 9. The product of any previous or subsequent aspect, wherein the product is a hydrogen tank or portion thereof.

[0098] Aspect 10. A process comprising: assembling and securing via welding the clad aluminum alloy product of any previous or subsequent aspect to a metal product.

[0099] Aspect 11. A process for producing a clad aluminum alloy product comprising a core layer and a cladding layer, the process comprising: co-casting an ingot having a core and a cladding on at least one outer surface of the core; and processing the ingot to form the clad aluminum alloy product, wherein the core layer comprises a first aluminum alloy that comprises up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum, and wherein the cladding layer comprises a second aluminum alloy that comprises up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0100] Aspect 12. The process of any previous or subsequent aspect, wherein the solutionizing step has a peak metal temperature of about 450 °C to about 545 °C.

[0101] Aspect 13. The process ofany previous or subsequent aspect, wherein the tempering step results in a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

[0102] Aspect 14. The process of any previous or subsequent aspect, wherein the first aluminum alloy comprises up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0103] Aspect 15. The process of any previous or subsequent aspect, wherein the second aluminum alloy comprises up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0104] Aspect 16. A process for producing a clad aluminum alloy product comprising a core layer and a cladding layer, the process comprising: joining the core layer and the cladding layer such that the cladding layer is bonded to at least one surface of the core layer; and wherein the core layer comprises a first aluminum alloy that comprises up to 1.2 wt. % Si, up to 1.3 wt.Attorney Docket No. 108050-1530025% Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum, and wherein the cladding layer comprises a second aluminum alloy that comprises up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0105] Aspect 17. The process of any previous or subsequent aspect, wherein a corrosion potential of the core layer is at least 50 mV greater than a corrosion potential of the cladding layer.

[0106] Aspect 18. The process of any previous or subsequent aspect, wherein the clad cladding layer has a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

[0107] Aspect 19. The process of any previous or subsequent aspect, wherein the first aluminum alloy comprises up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0108] Aspect 20. The process of any previous or subsequent aspect, wherein the second aluminum alloy comprises up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

[0109] 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. 108050-1530025WHAT IS CLAIMED IS:

1. A clad aluminum alloy product comprising: a core layer having a first surface and a second surface on opposing sides of the core layer, wherein the core layer comprises a first aluminum alloy that comprises up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum; and a cladding layer at one or both of the first surface and the second surface, wherein the cladding layer comprises a second aluminum alloy that comprises up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

2. The clad aluminum alloy product of claim 1, wherein a Cu content in the core layer is at least 3 wt. % greater than a Cu content in the cladding layer.

3. The clad aluminum alloy product of any preceding claim, wherein a corrosion potential of the core layer is at least 50 mV greater than a corrosion potential of the cladding layer.

4. The clad aluminum alloy product of any preceding claim, wherein a corrosion potential of the core layer is at least 40 mV greater than a corrosion potential of the cladding layer.

5. The clad aluminum alloy product of any preceding claim, wherein the cladding layer has a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

6. The clad aluminum alloy product of any preceding claim, wherein the first aluminum alloy comprises up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.Attorney Docket No. 108050-15300257. The clad aluminum alloy product of any preceding claim, wherein the second aluminum alloy comprises up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

8. A product fabricated with the clad aluminum alloy product of any preceding claim.

9. The product of claim 8, wherein the product is a hydrogen tank or portion thereof.

10. A process comprising: assembling and securing via welding the clad aluminum alloy product of one of claims 1-7 to a metal product.

11. A process for producing a clad aluminum alloy product comprising a core layer and a cladding layer, the process comprising: co-casting an ingot having a core and a cladding on at least one outer surface of the core; and processing the ingot to form the clad aluminum alloy product, wherein the core layer comprises a first aluminum alloy that comprises up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum, and wherein the cladding layer comprises a second aluminum alloy that comprises up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

12. The process of claim 11, wherein the solutionizing step has a peak metal temperature of about 450 °C to about 545 °C.

13. The process of any one of claims 11-12, wherein the tempering step results in a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.Attorney Docket No. 108050-153002514. The process of any one of claims 11-13, wherein the first aluminum alloy comprises up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

15. The process of any one of claims 11-14, wherein the second aluminum alloy comprises up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

16. A process for producing a clad aluminum alloy product comprising a core layer and a cladding layer, the process comprising: joining the core layer and the cladding layer such that the cladding layer is bonded to at least one surface of the core layer; and wherein the core layer comprises a first aluminum alloy that comprises up to 1.2 wt. % Si, up to 1.3 wt. % Fe, 1.9 wt. % to 9.0 wt. % Cu, up to 1.2 wt. % Mn, up to 1.8 wt. % Mg, up to 1.5 wt. % Ni, up to 0.1 wt. % Cr, up to 0.25 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum, and wherein the cladding layer comprises a second aluminum alloy that comprises up to 0.5 wt. % Si, up to 0.4 wt. % Fe, 0.5 wt. % to 2.8 wt. % Cu, up 0.5 wt. % Mn, up to 1 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

17. The process of claim 16, wherein a corrosion potential of the core layer is at least 50 mV greater than a corrosion potential of the cladding layer.

18. The process of claim 16 or 17, wherein the cladding layer has a T3 temper, T351 temper, T4 temper, T451 temper, T6 temper, T651 temper, T8 temper, T851 temper, or O temper.

19. The process of any one of claims 16-18, wherein the first aluminum alloy comprises up to 0.4 wt. % Si, up to 0.4 wt. % Fe, 5.5 wt. % to 7.5 wt. % Cu, up to 0.75 wt. % Mn, up to 0.1Attorney Docket No. 108050-1530025 wt. % Mg, up to 1.5 wt. % Ni, up to 0.05 wt. % Cr, up to 0.1 wt. % Zn, up to 0.15 wt. % Ti, up to 0.3 wt. % Zr, up to 0.2 wt. % V, up to 0.15 wt. % impurities, and aluminum.

20. The process of any one of claims 16-19, wherein the second aluminum alloy comprises up to 0.3 wt. % Si, up to 0.4 wt. % Fe, 0.5 to 1.6 wt. % Cu, up to 0.5 wt. % Mn, up to 0.7 wt. % Mg, up to 0.25 wt. % Cr, up to 0.3 wt. % Zn, up to 0.2 wt. % Ti, up to 0.3 wt. % Zr, up to 0.3 wt. % V, up to 0.15 wt. % impurities, and aluminum.

Images