High recycle content aluminum alloys and methods for preparing the same

Abstract

Described herein are 6xxx series aluminum alloys which exhibit a combination of good strength and formability despite having higher amounts of Si, Cu, and Fe than conventional 6xxx series aluminum alloys. The aluminum alloys described herein exhibit high strength and formability while simultaneously providing a recycle friendly alternative to 6xxx series aluminum alloys. The aluminum alloys described herein can allow for easier aluminum alloy scrap management and provide a low carbon footprint.

Description

Attorney Docket Number: 108050-1529930HIGH RECYCLE CONTENT ALUMINUM ALLOYS AND METHODS FOR PREPARING THE SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 717,590, filed November 7, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes.FIELD

[0001] The present disclosure relates to the fields of metallurgy, aluminum alloys, aluminum fabrication, and related fields. In particular, the present disclosure generally relates to aluminum alloys produced from a high content of recycled aluminum alloy materials and can tolerate high amounts of manganese (Mn) and silicon (Si) compared to conventional 6xxx series aluminum alloys, 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.BACKGROUND

[0002] 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. Even so, the use of currently available aluminum alloys in automotive applications poses certain challenges.

[0003] High strength 6xxx series aluminum alloys currently available on the market (e.g., AA6081 and AA6082) include low amounts of copper and / or silicon (e.g., less than 0.25 wt. % Cu and less than 1.20 wt. % Si). Typically, 6xxx series aluminum alloys are not produced from various sources of recycled aluminum alloy materials due to the high amounts of Cu and Si in the recycled material that can negatively affect the mechanical properties of 6xxx series aluminum alloys. This results in excess waste and requires more prime aluminum during alloy production. To compensate for increased amounts of Si in 6xxx series aluminum alloys, MgUS2008 32271052 1Attorney Docket Number: 108050-1529930 may be added in excess to account for the reduced strength attributed to high Si content. The addition of Mg, while adding strength, negatively impacts the aluminum alloy by making it more brittle, more prone to corrosion, and has significant costs. Thus, new 6xxx series aluminum alloys having a balanced composition to allow for incorporating recycled aluminum alloy materials while simultaneously maintaining the desired properties of standard 6xxx series alloys is highly desired.SUMMARY

[0004] Covered embodiments of the present disclosure are defined by the claims, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings and each claim.

[0005] Described herein are aluminum alloys that includes up to 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.20 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 1.40 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al. In some aspects, the aluminum alloy comprises up to 2.30 wt. % Si, up to 0.50 wt. % Fe, 0.11- 1.00 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.00 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al. In some aspect, the aluminum alloy comprises 1.00 - 2.40 wt. % Si, up to 0.50 wt. % Fe, 0.40 - 1.20 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.00 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti up, to 0.15 wt. % of impurities, and remainder Al. In some aspects, the aluminum alloy comprises up to 2.10 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 0.80 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and Al. In some aspects, the aluminum alloy comprises up to 2.00 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 0.50 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al. In some aspects, the aluminum alloy comprises up to 2.20 wt. % Si, up to 2.20 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30- 1.20 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al. In some aspects, a ratio of Si:Mg is from 1.00: 1 to 4.0: 1. In some aspects, the aluminum alloy has an average grain size of from 1 to 10 micron when in aAttorney Docket Number: 108050-1529930T4 temper. In some aspects, the aluminum alloy has a final bend angle of greater than 80° as measured according to VDA238-100 (2023) when in a T4 temper. In some aspects, the aluminum alloy is produced from less than 20 wt. % prime Al. In some aspects, the aluminum alloy has a yield strength of greater than 275 MPa when in a T8x temper. In some aspects, the aluminum alloy exhibits an increase in yield strength of 150 MPa or more when paint baked from 170° C to 200° C for 20 min to 30 min.

[0006] In some embodiments, a method or producing an aluminum alloy product, the method comprising: casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises up to 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.20 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 1.40 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al; homogenizing the cast product to produce a homogenized cast product; hot rolling the homogenized cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; and solution heat treating the final gauge rolled product to produce an aluminum alloy product; wherein the aluminum alloy product exhibits an increase in yield strength of 120 MPa or more when subjected to paint baking from 170° C to 200° C for 20 min to 30 min. In some aspects, the method further comprises aging the aluminum alloy product to a T temper prior to paint baking. In some aspects, the aluminum alloy product is aged to a T4 temper, a T6 temper, or a T8x temper. In some aspects, the method further comprises solidifying the cast product at a rapid solidification rate of at least 20° C / s. In some aspects, the aluminum alloy product has an average grain size from 3 to 15 micron. In some aspects, the aluminum alloy product has a bend angle of greater than 80° as measured according to VDA238-100 (2023) when in a T4 temper. In some aspects, prior to paint baking, the aluminum alloy product has a yield strength from 300 MPa to 500 MPa when in in T8x temper.

[0007] Further aspects, objects, and advantages will become apparent upon consideration of the detailed description and figures that follow.BRIEF DESCRIPTION OF THE FIGURES

[0008] FIG. 1A provides a graph of the yield strength (Rp) and ultimate tensile strength (Rm) for measurements taken in the L-direction for Example 1 and Example 2 aluminum alloys.

[0009] FIG. IB provides a graph of the yield strength (Rp) and ultimate tensile strength (Rm) for measurements taken in the T-direction for Example 1 and Example 2 aluminum alloys.Attorney Docket Number: 108050-1529930

[0010] FIG. 2 provides a graph of the total elongation (Ag (measured in %)) and uniform elongation (A80 (measured in %)) for measurements taken in the L-direction for Example 1 and Example 2 aluminum alloys in the T4 and T8x tempers.

[0011] FIG. 3A provides a graph of the bending angle measured in the longitudinal (L) direction and FIG. 3B provides a graph of the bending angle measured in the transverse (T) direction of Example 1 and Example 2 aluminum alloys.

[0012] FIGS. 4A provides electron backscatter diffraction (EBSD) images of the crystallographic structure for Examples 1 and 2, respectively.

[0013] FIG. 4B provides a graph of the texture analysis as measured in the EBSD for Example 1 and Example 2 aluminum alloys.

[0014] FIG. 4C provides the simulated r values for the Example 1 and Example 2 aluminum alloys.

[0015] FIG. 5 provides a graph of the measured hardness values for Example 1 in the as- cast condition and following a homogenization treatment.DETAILED DESCRIPTION

[0016] Described herein are novel aluminum alloys which exhibit a combination of good strength and formability despite having higher amounts of Si, Cu, and Fe, than conventional 6xxx series aluminum alloys. The aluminum alloys described herein provide high strength 6xxx series aluminum alloys including high amounts of Cu and Si that can replace other non-recycle friendly 6xxx series aluminum alloys that are typically used as strength-critical parts. Beneficially, aluminum alloys described herein improves recyclability and circularity of 6xxx series aluminum alloys. In particular, a high strength 6xxx series aluminum alloy that includes high amounts of Si, Cu, and Mn, while simultaneously having lower amounts of Mg, allows for the incorporation of high amounts of aluminum alloy scrap that has previously been unusable. The aluminum alloys described herein have a carefully controlled composition that achieves similar or better strength and formability properties than conventional high strength 6xxx series aluminum alloys. In some embodiments, the aluminum alloys described herein includes up to 2.48 wt. % Si, from 0.11 wt. % to 1.20 wt. % wt. % Cu, 0.30 wt. % to 1.40 wt. % Mg, and greater than 0.40 wt. % Mn (e.g., 0.40 wt. % to 1.20 wt. % Mn), which are outside the ranges of conventional AA6081 aluminum alloy. Surprisingly, it was found that adding 0.40 wt. % or more of Mn to the aforementioned composition can balance the effect of intermetallic formation (e.g., Fe-containing intermetallics) and also form alpha-phase intermetallic components, control grain size, and retard recrystallization.Attorney Docket Number: 108050-1529930

[0017] The aluminum alloys described herein provides a recycle friendly alternative to 6xxx series aluminum alloys. Beneficially, the aluminum alloys described herein provide a 6xxx series aluminum alloy that increases incorporation of recycle scrap previously unusable to produce 6xxx series aluminum alloys. Specifically, the present disclosure provides a 6xxx series aluminum alloy including a maximum of 2.48 wt. % Si and no greater than 1.40 wt. % Mg while allowing for up to 1.20 wt. % Cu, while exhibiting good strength and formability properties. The aluminum alloys described herein allows mixing of high strength 6xxx series aluminum alloy with other types of aluminum alloy scrap such as scrap from heat exchanger applications, tainted tabor, or extrusion profile applications. Additionally, the composition window of the aluminum alloys described herein is finely tuned in order to accept high recycling content (e.g., less prime aluminum) as compared to typical 6xxx series alloys. The aluminum alloys described herein provides a replacement for many high strength 6xxx series aluminum alloy including high amounts of Mg that promotes recyclability and circularity and allows for easier aluminum alloy scrap management and provides a low carbon footprint.

[0018] Additionally, the aluminum alloys described herein can be processed in a method such that the resulting metal products have high strength and high deformability properties. The properties of the metal products can be further enhanced during downstream processing (e.g., end user forming and post-forming heat treating the metal product, or end user paint baking). Surprisingly, due to aluminum alloy composition and the conditions used during the processing methods as further described herein, the metal products can achieve an increased final strength without degrading the final bendability or elongation. For example, the aluminum alloys described herein may be processed such that the aluminum alloy has a yield strength increase after paint baking the alloy (e.g., an increase in yield strength of greater than 100 MPa after paint bake).Definitions and Descriptions

[0019] As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0020] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “6xxx .” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, seeAttorney Docket Number: 108050-1529930“International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys,” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

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

[0022] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0023] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0024] 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 2.6 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.

[0025] 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.

[0026] 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 aluminumAttorney Docket Number: 108050-1529930 alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0027] 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.

[0028] All ranges disclosed herein are to be understood to encompass both endpoints and any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

[0029] 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.Alloy Compositions

[0030] Aluminum alloy properties are partially determined by the composition of the aluminum alloy. In certain aspects, the alloy composition may influence or even determine whether the alloy will have properties adequate for a desired application.Attorney Docket Number: 108050-1529930

[0031] Described herein are novel aluminum alloys produced from a combination of different recycled aluminum alloy materials. The aluminum alloy described herein is a modified 6xxx series aluminum alloy including a unique combination of alloying elements. The aluminum alloys exhibit high strength and formability, despite having higher contents of Si, Fe, Cu, and Mn than conventional 6xxx series aluminum alloys. The properties of the aluminum alloys are achieved due to the compositions and / or methods of making the alloys.

[0032] In some examples, an aluminum alloy as described herein can have the following elemental composition as provided in Table 1.Table 1

[0033] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 2.Table 2Attorney Docket Number: 108050-1529930

[0034] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 3.Table 3

[0035] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 4.Table 4Attorney Docket Number: 108050-1529930

[0036] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 5.Table 5

[0037] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 6.Table 6Attorney Docket Number: 108050-1529930

[0038] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 7.Table 7

[0039] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 8.Table 8Attorney Docket Number: 108050-1529930

[0040] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 9.Table 9

[0041] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 10.Table 10Attorney Docket Number: 108050-1529930

[0042] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 11.Table 11

[0043] In some examples, the aluminum alloy can have the following elemental composition as provided in Table 12.Table 12Attorney Docket Number: 108050-1529930Silicon (Si)

[0044] In some examples, the aluminum alloy described herein includes Si in an amount of up to 2.48% (e.g., up to 2.48%, from 0.30% to 2.40%, from 0.80% to 2.30%, from 1.20% to 2.48%, from 1.30% to 2.40%, from 1.40% to 2.30%, or from 1.40% to 2.20) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%,0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%,0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%,0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%,0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%,0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%,0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%,0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.00%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%,1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%,1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%,1.38%, 1.39%, 1.40%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%,1.50%, 1.51%, 1.52%, 1.53%, 1.54%, 1.55%, 1.56%, 1.57%, 1.58%, 1.59%, 1.60%, 1.61%,1.62%, 1.63%, 1.64%, 1.65%, 1.66%, 1.67%, 1.68%, 1.69%, 1.70%, 1.71%, 1.72%, 1.73%,1.74%, 1.75%, 1.76%, 1.77%, 1.78%, 1.79%, 1.80%, 1.81%, 1.82%, 1.83%, 1.84%, 1.85%,1.86%, 1.87%, 1.88%, 1.89%, 1.90%, 1.91%, 1.92%, 1.93%, 1.94%, 1.95%, 1.96%, 1.97%,1.98%, 1.99%, 2.00%, 2.01%, 2.02%, 2.03%, 2.04%, 2.05%, 2.06%, 2.07%, 2.08%, 2.09%,2.10%, 2.11%, 2.12%, 2.13%, 2.14%, 2.15%, 2.16%, 2.17%, 2.18%, 2.19%,%, 2.20%, 2.21%, 2.22%, 2.23%, 2.24%, 2.25%, 2.26%, 2.27%, 2.28%, 2.29%, 2.30%, 2.31%, 2.32%, 2.33%,2.34%, 2.35%, 2.36%, 2.37%, 2.38%, 2.39%, 2.40%, 2.41%, 2.42%, 2.43%, 2.44%, 2.45%,2.46%, 2.47%, of 2.48% Si. All expressed in wt.%. The aluminum alloy includes the aforementioned amounts of Si to compensate for the reduced elongation introduced from free silicon in the aluminum alloy.

[0045] As discussed herein, the aluminum alloy described herein includes a balance of alloying elements to exhibit the same strength as high magnesium 6xxx series aluminum alloys, while accommodating higher amount of recycled scrap and less prime aluminum. In order to reach the same level of strength and formability of 6xxx aluminum alloys including high amounts of Mg (greater than 0.59 wt.%), the amount of Si is provided in a range from up toAttorney Docket Number: 108050-15299302.48 wt.%. In parallel, the aluminum alloy described herein includes a higher amount of scrap content. For example, the scrap content may be predominantly from heat exchange scrap.Iron (Fe)

[0046] In some examples, the aluminum alloy described herein also includes Fe in an amount of from 0.20% to 0.50% (e.g., from 0.20% to 0.45%, from 0.20% to 0.40%, or from 0.25% to 0.40%) based on the total weight of the alloy. For example, the alloy can include 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%, or 0.50% Fe. All expressed in wt. %. The aluminum alloy described herein tolerates higher amounts of Fe to be able to absorb more recycled aluminum scrap without negatively affecting the properties of the aluminum alloy. One of the main alloying elements present in recycled aluminum scrap is Fe. When the amount of Si increases, the critical amount of Fe that leads to formation of the detrimental P-AlFeSi can be calculated as Fecriticai (wt. %) = 0.075 * (wt. % Si) - 0.05. Thus, increasing Si and Fe content in the aluminum will increase formation of P-AlFeSi. It was unexpectedly found that including Mn in the amounts described herein can prevent beta phase formation, and control and prevent grain size growth. This beneficially allows the aluminum alloys described herein to achieve a good paint bake response.Copper (Cu)

[0047] In some examples, the aluminum alloy described herein includes Cu in an amount of from 0.11% to 1.20% (e.g., from 0.15% to 1.15%, from 0.20% to 1.10%, from 0.30% to 1.00%, from 0.11% to 0.50%, from 0.11% to 0.45%, from 0.11% to 0.40%, or from 0.11% to 0.35%) based on the total weight of the alloy. For example, the alloy can include 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%, 0.77%, 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. %.Attorney Docket Number: 108050-1529930Manganese (Mn)

[0048] In some examples, the aluminum alloy described herein can include Mn in an amount from 0.40% to 1.20% (e.g., from 0.50% to 1.20%, from 0.60% to 1.20%, from 0.10% to 0.30%, from 0.20% to 0.30%, or from 0.20% to 0.25%) based on the total weight of the alloy. For example, the alloy can include 0.40%, 0.41%, 0.42%, 0.43%, 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%, or 1.20% Mn. Due to the higher amounts of Si in the aluminum alloys described herein, the Mn is optimized to avoid precipitation of beta-phase particles. In some embodiments, the aluminum alloy includes at least 0.40 wt. % Mn (e.g., 0.40 wt. % to 1.20 wt. %) to avoid precipitation of beta-phase particles. In some embodiments, the Mn content in the aluminum alloy is limited to up to 1.20 wt. % (e.g., up to 1.10 wt. % or up to 1.00 wt.%) as the Mn will lead to an increase in density of dispersoids in the aluminum alloy microstructure. The increase in the density of dispersoids reduces the grain size and increases the strength of the aluminum alloy; however, formability is not necessarily improved. Additionally, the increase in Mn content pins grain boundaries and reduces the energy of grain boundary to migrate and become larger (e.g., reduced the grain growth of the aluminum alloy microstructure).Magnesium (Mg)

[0049] In some examples, the aluminum alloy described herein can include Mg in an amount from 0.30% to 1.40% (e.g., from 0.30% to 0.55%, from 0.30% to 0.50%, from 0.30% to 1.30%, or from 0.30% to 1.20%) based on the total weight of the alloy. For example, the alloy can include 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%,Attorney Docket Number: 108050-15299301.24%, 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% of Mg. All expressed in wt. %.

[0050] As discussed herein, the aluminum alloy described herein includes a balance of alloying elements to exhibit the same strength as high Mg 6xxx series aluminum alloys, while accommodating higher amounts of Si, Fe, and Mn and a reduced amount of Mg as compared to 6xxx series alloys. For example, the aluminum alloy described herein may have a ratio of Si to Mg of from 1.00: 1 to 4.0: 1. For example, the ratio of Si:Mg may be 1.00: 1, 1.10: 1, 1.20: 1, 1.30: 1, 1.40: 1, 1.50: 1, 1.60: 1, 1.70: 1, 1.80: 1, 1.90: 1, 2.0:1, 2.10: 1, 2.20: 1, 2.30: 1, 2.40: 1, 2.50: 1, 2.60: 1, 2.70: 1, 2.80: 1, 2.90: 1, 3.0: 1, 3.10: 1, 3.20: 1, 3.30: 1, 3.40: 1, 3.50: 1, 3.60: 1, 3.70: 1, 3.80: 1, 3.90: 1, or 4.0: 1.Zinc (Zn)

[0051] In some examples, the aluminum alloy described herein can include Zn in an amount up to 0.50% (e.g., up to 0.45%, up to 0.40%, up to 0.10%, from 0.01% to 0.50%, from 0.05% to 0.45%, or from 0.05% to 0.35%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%,0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%,0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%,0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%,0.46%, 0.47%, 0.48%, 0.49%, or 0.50% Zn. All expressed in wt. %.Titanium (Ti)

[0052] In some examples, the aluminum alloy described herein includes Ti in an amount up to 0.15% (e.g., up to 0.14%, up to 0.12%, up to 0.10%, from 0.01% to 0.15%, or from 0.05% to 0.15%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 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%, or 0.15% Ti. All expressed in wt. %.Chromium (Cr)

[0053] In some examples, the aluminum alloy described herein includes Cr in an amount up to 0.25% (e.g., up to 0.20%, up to 0.15%, up to 0.10%, from 0.01% to 0.25%, or from 0.05% to 0.25%) 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%, or 0.25% Cr. All expressed in wt.%.Minor ElementsAttorney Docket Number: 108050-1529930

[0054] Optionally, the aluminum alloys described herein can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01% or below. These impurities may include, but are not limited to Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Accordingly, Ti, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be present in alloys in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01% or below. The sum of all impurities does not exceed 0.15% (e.g., 0.1%). All expressed in wt.%. The remaining percentage of each alloy can be aluminum.Properties

[0055] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 300 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 300 MPa or greater, 310 MPa or greater, 320 MPa or greater, 330 MPa or greater, or 350 MPa or greater, when in a T6 temper. In some cases, the yield strength is from 300 MPa to 500 MPa (e.g., from 310 MPa to 500 MPa, from 320 MPa to 500 MPa, from 320 MPa to 480 MPa, or from 320 MPa to 460 MPa), or anywhere in between, when in a T6 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.

[0056] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 150 MPa or greater when in a T4 or T8x temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 150 MPa or greater, 175 MPa or greater, 200 MPa or greater, 225 MPa or greater, or 250 MPa or greater, when in a T4 or T8x temper. In some cases, the yield strength is from 150 MPa to 500 MPa (e.g., from 160 MPa to 500 MPa, from 170 MPa to 500 MPa, from 180 MPa to 480 MPa, or from 200 MPa to 460 MPa), or anywhere in between, when in a T4 or T8x 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.

[0057] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have an ultimate tensile strength of about 200 MPa or greater 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 orAttorney Docket Number: 108050-1529930 greater, 255 MPa or greater, or 260 MPa, 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 280 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.

[0058] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a total 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 total elongation of 16% or greater, 17% or greater, 18% or greater, 19% or greater, or 20% or greater, when in a T4 temper. In some cases, the total elongation is from 15% to 25% (e.g., from 15% to 23%, from 16% to 23%, from 18% to 23%, or from 20% to 23%), 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.

[0059] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 17% 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 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 uniform elongation is from 20% to 28% (e.g., from 21% to 28%, from 22% to 28%, from 23% to 26%, or from 23% to 25%), 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.

[0060] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a VDA bending angle from 30° to 110° when in a T4 temper (e.g., from 35° to 100°, from 35° to 90°, or from 40° to 95°). For example, an aluminum alloy product produced from the aluminum alloys described herein can have a VDA bending angle of about 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, 90°, 95°, 100°, 105°, or 110° when in a T4 temper, or anywhere in between.

[0061] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation of 6% or greater when in a T4 temper or a T8xAttorney Docket Number: 108050-1529930 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, or 9% or greater, when in a T4 or T8x temper. In some cases, the total elongation is from 6% to 25% (e.g., from 8% to 20%, from 10% to 20%, or from 12% to 20%), or anywhere in between, when in a T4 or T8x temper. In some embodiments, the aluminum alloy described herein can have a total elongation of 7% or greater 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.

[0062] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 5% or greater when in a T4 or T8x temper. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation of 5% or greater, 6% or greater, 7% or greater, or 8% or greater, when in a T4 or T8x temper. In some cases, the uniform elongation is from 5% to 15% (e.g., from 5% to 14%, from 6% to 14%, from 6% to 13%, or from 5% to 12%), or anywhere in between, when in a T4 or T8x temper. In some embodiments, an aluminum alloy product produced from the aluminum alloys described herein can have a uniform elongation as described above when in a T6 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.

[0063] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a grain size of below 15 pm. For example, the grain size may be from 1 pm to 15 pm, from 1 pm to 10 pm, from 1 pm to 8 pm, or from 1 pm to 5 pm. In some embodiments, the grain size may be below 5 pm. For example, the aluminum alloy product produced herein may have a reduced grain size in part due to the alloy composition and additionally in part due to the processing methods described herein.

[0064] In certain aspects, a paint bake response is observed wherein the alloys exhibit an increase in yield strength. In certain examples, the paint bake response is employed to complete an artificial aging process initiated by a pre-aging step employed during aluminum alloy production. In certain examples, the alloys can be used in an exemplary temper as described herein. In certain aspects, the alloys and methods described herein results in a high-strength alloy including formability properties normally observed in lower strength alloys. Additionally,Attorney Docket Number: 108050-1529930 the resulting exemplary temper can provide alloys that may not naturally age-harden over time. A non-natural aging alloy can be stored indefinitely and retain desirable mechanical properties including high-strength, high formability and a favorable paint bake response. For example, the aluminum alloy products described herein can have an increase in yield strength for example, can have an increase of greater than 100 MPa (e.g., greater than 110 MPa, greater than 120 MPa, greater than 130 MPa, greater than 140 MPa, or greater than 150 MPa) after paint bake.Methods of Making Aluminum Alloys

[0065] 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 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. In some embodiments, the casting device can be configured to provide solidification rates of at least 1 °C / s, at least 5 °C / s, at least 10 °C / s, at least 25 °C / s, at least 50 °C / s, or at least 100 °C / s) and fast cooling (e.g., quickly cooling at rates of at least 1 °C / s, at least 5 °C / s, at least 10 °C / s, at least 25 °C / s, at least 50 °C / s, or at least 100 °C / s) of the metal strip, which can facilitate improved microstructure in the final metal strip. In some cases, the solidification rate can be at or above 10 times the solidification rate of traditional DC casting. In some embodiments, the aluminum alloy, prior to casting, may be book molded at an initial gauge thickness. For example, the initial gauge alloy can be molded using a copper mold. In some embodiments, the molding step can be incorporated in the processing of the aluminum alloy to aid in rapidly cooling the aluminum alloy.

[0066] Traditionally, fast solidification has been avoided because the resulting metal strip has undesirable characteristics. However, it has been surprisingly discovered that the aluminum alloy described herein in combination with the speed of solidification as well as the slow diffusion of dispersoid-forming elements, continuously cast metal strips exhibit a fairly homogeneous structure with many of the dispersoid-forming elements in solution. In contrast, a DC cast ingot may have significant amounts of coring, which require homogenization for long periods of time. This fast solidification of continuously cast metal strips of the aluminum alloy described herein homogenizes eutectic-forming elements, but promotes formation of alpha-phase and controls the growth of grain boundaries, thereby preventing recrystallization. Without being bound by theory, it is believed that fast solidification along with the disclosedAttorney Docket Number: 108050-1529930 elements in the aluminum alloy exiting a continuous casting line can, along with other techniques discussed herein, help ensure a controlled grain growth and prevents recrystallization. In some embodiments, the aluminum alloy has an unrecrystallized microstructure.

[0067] 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, a cold rolling step, and an optional continuous annealing and solution heat treatment (CASH) 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. In some embodiments, the processing steps described below can also be performed after the optional CASH step.

[0068] In a homogenization step, a cast product may be heated to a homogenization temperature, such as a temperature from 500 °C to 580 °C (e.g., from 500 °C to 570 °C, from 520 °C to 580 °C, from 520 °C to 560 °C, from 535 °C to 570 °C, from 535 °C to 580 °C, from 534 °C to 560 °C, or from 530 °C to 550 °C). For example, the cast product can be heated to a temperature of 510 °C, 515 °C, 520 °C, 525 °C, 530 °C, 535 °C, 540 °C, 545 °C, 550 °C, 555 °C, 560 °C, 565 °C, 570 °C, 575 °C, or 580 °C. In some embodiments, the homogenization temperature is greater than 540 °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 10 hours.

[0069] Following a homogenization step, a hot rolling step can be performed. In some embodiments, the homogenized product is hot rolled directly after homogenization. The entry temperature to the hot rolling step can be the same as the homogenization temperature. 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, there is no cooling of the homogenized product prior to the start of hot rolling. 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 a hot rolling temperature ranging from 500 °C to 600 °C (e.g., from 510 °C to 590 °C, from 520 °C to 580 °C, from 520 °C to 570 °C, from 520 °C to 560 °C, from 520 °C to 550 °C, from 525 °C to 560 °C, from 530 °C to 555 °C, or from 530 °C to 550 °C). For example, the homogenized product can be hot rolled at a hot rolling temperature of 500 °C, 510 °C, 520 °C, 530 °C, 540 °C, 550 °C, 560 °C, 570 °C, 580 °C, 590 °C, or 600 °C. In some instances, theAttorney Docket Number: 108050-1529930 aluminum alloy product as cast is hot rolled to reduce the gauge thickness of the aluminum alloy. For example, the aluminum alloy may be reduced by more than 50% in thickness in the hot rolling step (e.g., more than 55%, more than 60%, more than 65%, more than 75%, or more than 80%).

[0070] The hot rolled product can be cold rolled using cold rolling mills into thinner products, such as a final gauge rolled product. The final gauge rolled product can have a gauge between 0.5 to 10 mm, e.g., between 0.7 to 6.5 mm. Optionally, the final gauge 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 at least 50% (e.g., at least 50%, at least 60%, at least 70%, at least 80%, or at least 85% 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. Optionally, the process for producing the aluminum alloy can include an interannealing step (e.g., between one or more cold rolling steps).

[0071] Following hot rolling or cold rolling, the final gauge rolled product can be solution heat treated. For example, the final gauge rolled product can be heated to a peak metal temperature for solution heat treatment (directly) after cold rolling. 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 (e.g., from 420 °C to 580 °C, from 440 °C to 570 °C, from 450 °C to 570 °C, from 460 °C to 570 °C, from 470 °C to 570 °C, from 480 °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 seconds 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 550 °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.

[0072] 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 peakAttorney Docket Number: 108050-1529930 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.

[0073] In certain aspects, the final gauge rolled product is pre-aged prior to artificial aging the aluminum alloy product. The final gauge rolled product may be pre-aged for a period of time to result in a pre-aged final gauge rolled product. For example, the final gauge rolled product can be pre-aged at a temperature from 70 °C to 140 °C (e.g., 70 °C, 72 °C, 74 °C, 76 °C, 78 °C, 80 °C, 82 °C, 84 °C, 86 °C, 88 °C, 90 °C, 92 °C, 94 °C, 96 °C, 98 °C, 100 °C, 102 °C, 104 °C, 106 °C, 108 °C, 110 °C, 112 °C, 114 °C, 116 °C, 118 °C, 120 °C, 122 °C, 124 °C, 126 °C, 128 °C, 130 °C, 132 °C, 134 °C, 136 °C, 138 °C, or 140 °C) for a period of time. Optionally, the pre-aging may be for a period of from 15 minutes to 4 hours (e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, or anywhere in between) to result in the pre-aged final gauge rolled product.

[0074] In certain aspects, the final gauge rolled product is aged to a temper (e.g., after preaging). The final gauge rolled product can be naturally aged or artificially aged for a period of time to result in T temper. For example, the final gauge rolled product can be aged to T4 temper, a T6 temper, or a T8x temper. In certain aspects, the final gauge rolled product can be artificially aged (AA) at a temperature from 160 °C to 250 °C (e.g., 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 final gauge rolled product can be artificially aged for a period from 15 minutes to 8 hours (e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, or 8 hours or anywhere in between) to result in the T6 temper.

[0075] In certain aspects, the final gauge rolled product may be subject to paint baking (e.g., after aging to a temper). The paint baking may include applying a 2% strain on the final gauge rolled product prior to or during heating to the paint bake temperature. The final gauge rolled product may can be subjected to heat treatment in an oven. The temperature for paint bake may range from about 170 °C to 200 °C (e.g., 170 °C, 175 °C, 180 °C, 185 °C, 190 °C, 195 °C, or 200 °C) for a period of time. In some embodiments, the period of time the final gauge rolled product may is paint baked may be from 10 minutes to 40 minutes (e.g., 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes, or 40 minutes).

[0076] In some embodiments, the solution heat treated aluminum alloy can be subjected to pre-aging. For example, the solution heat treated aluminum alloy can be heated to an elevated temperature and then allowed to cool to ambient (e.g., room temperature) over a period of time.Attorney Docket Number: 108050-1529930The pre-aged aluminum alloy can then be subjected to cold rolling, naturally aging, and artificial aging as described herein.

[0077] The aluminum alloy described herein is suitable for use in the manufacturing of products formed by plastic forming processes such as 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.Recycled Content Alloys

[0078] 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 alloy 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.

[0079] The aluminum alloys described herein can tolerate high amounts of recycled scrap and still exhibit desirable mechanical properties. The impact of the impurities and / or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing a specific aluminum alloy composition to compensate for the impurities. This enables a higher amount of less expensive, higher impurity aluminum scrap for producing aluminum alloys that can still exhibit desirable properties.

[0080] In some aspects, the aluminum alloy can be produced from up to 100% recycled scrapAttorney Docket Number: 108050-1529930

[0081] (e.g., from 70% to 100%, from 75% to 100%, from 80% to 100%, or from 90% to100%), based on the total weight of the aluminum alloy. All are expressed in wt. %.

[0082] In some embodiments, prime aluminum alloy can be used in combination with the recycled scrap to produce the aluminum alloys described herein. 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.Illustrations of Suitable Methods and Alloy Products

[0083] Illustration 1 is an aluminum alloy comprising up to 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.20 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 1.40 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

[0084] Illustration 2 is the aluminum alloy of any preceding or subsequent illustration, comprising up to 2.30 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.00 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.00 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

[0085] Illustration 3 is the aluminum alloy of any preceding or subsequent illustration, comprising 1.00 - 2.40 wt. % Si, up to 0.50 wt. % Fe, 0.40 - 1.20 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.00 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti up, to 0.15 wt. % of impurities, and remainder Al.

[0086] Illustration 4 is the aluminum alloy of any preceding or subsequent illustration, comprising up to 2.10 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 0.80 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and Al.

[0087] Illustration 5 is the aluminum alloy of any preceding or subsequent illustration, comprising up to 2.00 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 0.50 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

[0088] Illustration 6 is the aluminum alloy of any preceding or subsequent illustration, comprising up to 2.20 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.20 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.Attorney Docket Number: 108050-1529930

[0089] Illustration 7 is the aluminum alloy of any preceding or subsequent illustration, wherein a ratio of Si:Mg is from 1.00: 1 to 4.0: 1.

[0090] Illustration 8 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has an average grain size of from 1 to 10 micron when in a T4 temper.

[0091] Illustration 9 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has a final bend angle of greater than 80° as measured according to VDA238-100 (2023) when in a T4 temper.

[0092] Illustration 10 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy is produced from less than 20 wt. % prime Al.

[0093] Illustration 11 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has a yield strength of greater than 275 MPa when in a T8x temper.

[0094] Illustration 12 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy exhibits an increase in yield strength of 150 MPa or more when paint baked from 170° C to 200° C for 20 min to 30 min.

[0095] Illustration 13 is A method of producing an aluminum alloy product, the method comprising: casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises up to 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.20 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 1.40 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al; homogenizing the cast product to produce a homogenized cast product; hot rolling the homogenized cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; and solution heat treating the final gauge rolled product to produce an aluminum alloy product; wherein the aluminum alloy product exhibits an increase in yield strength of 120 MPa or more when subjected to paint baking from 170° C to 200° C for 20 min to 30 min.

[0096] Illustration 14 is the method of any preceding or subsequent illustration, further comprising aging the aluminum alloy product to a T temper prior to paint baking.

[0097] Illustration 15 is the method of any preceding or subsequent illustration, wherein the aluminum alloy product is aged to a T4 temper, a T6 temper, or a T8x temper.

[0098] Illustration 16 is the method of any preceding or subsequent illustration, further comprising solidifying the cast product at a rapid solidification rate of at least 20° C / s.

[0099] Illustration 17 is the method of any preceding or subsequent illustration, wherein the aluminum alloy product has an average grain size from 3 to 15 micron.Attorney Docket Number: 108050-1529930

[0100] Illustration 18 is the method of any preceding or subsequent illustration, wherein the aluminum alloy product has a bend angle of greater than 80° as measured according to VDA238-100 (2023) when in a T4 temper.

[0101] Illustration 19 is the method of any preceding or subsequent illustration, wherein, prior to paint baking, the aluminum alloy product has a yield strength from 300 MPa to 500 MPa when in in T8x temper.

[0102] Illustration 20 is the method of any preceding or subsequent illustration, wherein the aluminum alloy comprises 1.00 - 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.50 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 0.59 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.EXAMPLES

[0103] All patents, publications, and abstracts cited above are incorporated herein by reference in their entireties. Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptions thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims. Example 1

[0104] Sample aluminum alloys were tested to determine the properties of the aluminum alloys described herein. Example Alloys 1 and 2 were prepared according to the following method. The aluminum alloy compositions in Table 13 were cast in a book mold at an initial thickness of 10 mm. The cast aluminum alloy was trimmed to 8 mm and heated to a homogenization temperature of 540 °C at a heating rate of 50 °C / h and soaked at the homogenization temperature for 6 hours. The homogenized aluminum alloy was hot rolled to 3.5 mm (56% thickness reduction) to produce a hot rolled product. The hot rolled product was cold rolled to 1 mm (71% thickness reduction) to produce a cold rolled product. The cold rolled product was solution heat treated at 540 °C for 60 seconds followed by water quenching to produce the aluminum alloy product. The aluminum alloy product was preaged at 90 °C for 2 hours followed by artificial aging at 2% pre-strain to provide the aluminum alloy product in a T8x temper. Table 13 provides the aluminum alloy composition for each of Examples 1 and 2.Table 13Attorney Docket Number: 108050-1529930

[0105] As shown in Table 13, Examples 1 and 2 are 6xxx series aluminum alloys including greater than 1.00 wt. % Si and less than 0.60 wt. % Mg. As discussed herein, 6xxx series aluminum alloys including high amounts of Mg and lower amounts of Mn, Fe, and Cu have limited ability to incorporate recycled content. However, the 6xxx series aluminum alloys are typically used in automotive applications due to their combination of excellent strength and bendability. The aluminum alloys described herein have a carefully controlled composition that achieves comparable strength and formability / bendability properties as conventional 6xxx series aluminum alloys despite having a maximum of 1.40 wt. % Mg. Beneficially, the aluminum alloys described herein promote circularity for recycled aluminum alloys due to the incorporation of higher amounts of Mn, Fe, and Cu content and can incorporate greater than 50 % recycled content.

[0106] The yield strength, ultimate tensile strength, and elongation were evaluated for Example Alloys 1 and 2 to understand the effects of amounts of Mn greater than 0.40 wt. % on the mechanical properties of the 6xxx series aluminum alloys. FIG. 1A provides a graph of the yield strength (Rp) and ultimate tensile strength (Rm) measured in the L-direction for Example 1 and Example 2 aluminum alloys. FIG. IB provides a graph of the yield strength (Rp) and ultimate tensile strength (Rm) in the T-direction for Example 1 and Example 2 aluminum alloys. The graphs show the relative affect the increase in Mn has on the overall performance of the yield strength and ultimate tensile strength. For example, Example 1 aluminum alloy includes 0.80 wt. % Mn and Example 2 aluminum alloy includes 1.10 wt. % Mn. Example 1 aluminum alloy has a yield strength of about 175 MPa in a T4 temper and about 325 MPa in a T8x temper, both in the L-direction. Example 2 aluminum alloy has a yield strength of 150 MPa in a T4 temper and under 300 in a T8x temper. In comparison, while the composition is not shown here, a comparable 6xxx series aluminum alloy (AA6081 aluminum alloy) which includes higher amounts of Mg, has a yield strength of 338 MPa when in a T6 Temper in both the L and T-directions. The graphs further demonstrate the increase in yield strength of the aluminum alloy compositions after paint baking the aluminum alloys, known as paint bake response (PBR). Thus, the yield strength and ultimate tensile strength graphs show the influence that different amounts and ranges of Mn can have on the strength of aluminum alloys in different tempers. When comparing the aluminum alloys described herein to a known 6xxxAttorney Docket Number: 108050-1529930 series aluminum alloy, the yield strength and ultimate tensile strength of the alloys described herein are comparable while also allowing for higher recycle content that was previously unusable. Thus, aluminum alloys described herein provide a more economically and environmentally high strength aluminum alloy.

[0107] FIG. 2 provides a graph of the total elongation (Ag (in %)) and uniform elongation (A80 (in %)) for Example 1 and Example 2 aluminum alloys in both T4 and T8x tempers. Each aluminum alloy was subjected to the same number of elongation tests in the longitudinal (L) direction. Examples 1 and 2 exhibit comparable total and uniform elongation properties under all temper conditions tested (T4 and T8x). Example 1 aluminum alloy, having less Mn than Example 2, exhibited a slightly higher total and uniform elongation in the T4 temper. In the T8x temper, Example 2 aluminum alloy surprisingly had a higher uniform elongation.

[0108] FIG. 3A provides a graph of the bending angle in the longitudinal (L) direction and FIG. 3B provides a graph of the bending angle of Example 1 and Example 2 aluminum alloys in the transverse (T) direction. The bending angle of the Example alloys demonstrate that by tailoring the aluminum alloy composition by increasing the Mn content from 0.80 (Example 1 alloy) to 1.10 (Example 2 alloy), increasing the Si content from 0.90 to 1.50, and decreasing the Cu, Mg, Cr, and Ti content, the bending angle improves. For example, the bending angle exhibited by Example 1 was 109.9 in the L direction, while Example 2 alloy exhibited a bending angle of 83.4. A similar trend is observed in the T direction where the lower Mn content in the aluminum alloy improves the bending angle.

[0109] FIG. 4A show the electron backscatter diffraction (EBSD) analysis for Examples 1 and 2, respectively, and FIG. 4B provides a graph of the texture analysis as measured in the EBSD for Example 1 and Example 2 aluminum alloys. Example 1 and Example 2 exhibited a similar average diameter for the grains of about 13 and 12 micron, respectively. Interestingly, Example 2 alloy exhibited more Q phase and cube phase textures as compared to Example 1 alloy. The EBSD results indicate that by incorporating higher amounts of Mn into the aluminum alloy, the grain size can be controlled and fined tuned to reduce the grain size to lower than 10 micron and further stabilize the alpha phase of the aluminum alloys. The results, taken together, suggest that by fine tuning the aluminum alloy composition and further the processing methods used can allow for an aluminum alloy exhibiting high strength and formability comparable to high Mg 6xxx series alloys while allowing for high recycle content.

[0110] Additional testing was performed to assess the effect of homogenization conditions on the hardness values of the Example 1 aluminum alloy. An cast alloy of Example 1 was homogenized at a temperature of 550 °C and soaked at the homogenization temperature for 4Attorney Docket Number: 108050-1529930 hours followed by water quenching. The heating rate to the homogenization temperature was 100 °C / h. As shown in FIG. 5, the results demonstrated an increase in 40 HV in hardness value after homogenization compared to the as cast product of Example 1. The increased hardness is attributed, in part, to the dispersoid and precipitation formation during homogenization. This hardness increase is equivalent to about 100 MPa increase in the strength on the aluminum alloy after processing (e.g., after rolling, solution heat treatment, etc.). The increased hardness values can improve the properties of resulting aluminum alloy for use in structural components.

Claims

Attorney Docket Number: 108050-1529930WHAT IS CLAIMED IS:

1. An aluminum alloy comprising up to 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.20 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 1.40 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

2. The aluminum alloy of claim 1, wherein the aluminum alloy comprises up to 2.30 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.00 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.00 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

3. The aluminum alloy of claim 1, wherein the aluminum alloy comprises 1.00 - 2.40 wt. % Si, up to 0.50 wt. % Fe, 0.40 - 1.20 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.00 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti up, to 0.15 wt. % of impurities, and remainder Al.

4. The aluminum alloy of claim 1, wherein the aluminum alloy comprises up to 2.10 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 0.80 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and Al.

5. The aluminum alloy of claim 1, wherein the aluminum alloy comprises up to 2.00 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 0.50 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

6. The aluminum alloy of claim 1, wherein the aluminum alloy comprises up to 2.20 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.80 wt. % Cu, 0.50 - 1.20 wt. % Mn, 0.30 - 1.20 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al.

7. The aluminum alloy of claim 1, wherein a ratio of Si:Mg is from 1.00: 1 to 4.0: l.Attorney Docket Number: 108050-15299308. The aluminum alloy of claim 1, wherein the aluminum alloy has an average grain size of from 1 to 10 micron when in a T4 temper.

9. The aluminum alloy of claim 1, wherein the aluminum alloy has a final bend angle of greater than 80° as measured according to VDA238-100 (2023) when in a T4 temper.

10. The aluminum alloy of claim 1, wherein the aluminum alloy is produced from less than 20 wt. % prime Al.

11. The aluminum alloy of claim 1, wherein the aluminum alloy has a yield strength of greater than 275 MPa when in a T8x temper.

12. The aluminum alloy of claim 1, wherein the aluminum alloy exhibits an increase in yield strength of 150 MPa or more when paint baked from 170 °C to 200 °C for 20 min to 30 min.

13. A method of producing an aluminum alloy product, the method comprising: casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises up to 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 1.20 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 1.40 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al; homogenizing the cast product to produce a homogenized cast product; hot rolling the homogenized cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; and solution heat treating the final gauge rolled product to produce an aluminum alloy product; wherein the aluminum alloy product exhibits an increase in yield strength of 120 MPa or more when subjected to paint baking from 170 °C to 200 °C for 20 min to 30 min.Attorney Docket Number: 108050-152993014. The method of claim 13, further comprising aging the aluminum alloy product to a T temper prior to paint baking.

15. The method of claim 14, wherein the aluminum alloy product is aged to a T4 temper, a T6 temper, or a T8x temper.

16. The method of claim 13, further comprising solidifying the cast product at a rapid solidification rate of at least 20 °C / s.

17. The method of claim 13, wherein the aluminum alloy product has an average grain size from 3 to 15 micron.

18. The method of claim 13, wherein the aluminum alloy product has a bend angle of greater than 80° as measured according to VDA238-100 (2023) when in a T4 temper.

19. The method of claim 13, wherein, prior to paint baking, the aluminum alloy product has a yield strength from 300 MPa to 500 MPa when in in T8x temper.

20. The method of claim 13, wherein the aluminum alloy comprises 1.00 - 2.48 wt. % Si, up to 0.50 wt. % Fe, 0.11 - 0.50 wt. % Cu, 0.40 - 1.20 wt. % Mn, 0.30 - 0.59 wt. % Mg, up to 0.25 wt. % Cr, up to 0.50 wt. % Zn, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and remainder Al

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