High recycle content 3xxx series aluminum alloys for use in roller shutters and garage doors

Abstract

Described herein are 3xxx series aluminum alloys including recycled aluminum alloy materials which exhibit the requisite strength and formability for slats for roller shutters and garage doors. The 3xxx series aluminum alloys described herein are suitable for use as, for example, garage doors (e.g., garage door panels) and roller shutters. The present disclosure provides an environmentally friendly and cost-effective alternative to the use of AA5006 aluminum alloys for garage door panels and roller shutters and exhibits comparable or better mechanical properties than AA5006 aluminum alloys.

Description

KT Ref. 108050-1523998HIGH RECYCLE CONTENT 3XXX SERIES ALUMINUM ALLOYS FOR USE IN ROLLER SHUTTERS AND GARAGE DOORSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 720,975, filed November 15, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes.FIELD

[0002] The present disclosure relates to the fields of metallurgy, aluminum alloys, aluminum fabrication, and related fields. In particular, the present disclosure is directed to aluminum alloys (e.g., 3xxx series aluminum alloys) produced from a high content of recycled aluminum alloy materials that have various end uses, such as in garage doors and roller shutters.BACKGROUND

[0003] Aluminum alloys are used in many different applications that require a combination of strength and durability. However, currently available aluminum alloys include significant amounts of primary aluminum. Primary aluminum is aluminum originating from aluminum -enriched ore, such as bauxite. Primary aluminum contributes significantly to carbon impact for producing aluminum alloys as mining and extracting aluminum from bauxite is a labor-intensive and capital-intensive process.

[0004] Many original equipment manufacturers require recycle-friendly aluminum alloys to comply with federal regulations or to limit their carbon footprint. Therefore, aluminum alloys that are produced from high amounts of recycled aluminum alloy materials and less primary aluminum are in overwhelming demand. However, aluminum alloys have strictly controlled compositional ranges to meet specific performance properties. Additionally, recycled aluminum alloy materials may include a mixture of different aluminum alloy compositions resulting in an aluminum alloy microstructure having a higher area fraction of secondary phases with different ratios for each secondary phase. The aluminum alloy microstructure for an aluminum alloy produced from recycled aluminum materials can be detrimental for the formability of the alloys.

[0005] For example, AA5006 aluminum alloys are commonly used for slats for roller shutter and garage door applications. The AA5006 aluminum alloy includes high amounts of primary aluminum. The high primary aluminum content leads to higher energy consumptionKT Ref. 108050-1523998and carbon emissions compared to an aluminum alloy produced from recycled aluminum materials. The recycling of aluminum scrap is a very attractive proposition in that up to 95% of the energy costs can be saved when compared with the laborious extraction of the more costly primary aluminum.BRIEF DESCRIPTION OF DRAWINGS

[0006] FIG. 1A shows an example backscattered electron image using a Scanning Electron Microscope (SEM). FIG. IB shows an example of an SEM image analysis using the commercially available software AZtec from Oxford Instrument that provides automated feature analysis of particles of the backscattered electron image (FIG. 1 A) to identify particles based on their grayscale levels.

[0007] FIGs. 2A-2C show a backscattered electron image (top image) of the microstructure of the example alloys and particle detection by greyscale image analysis for the example alloys (bottom image).SUMMARY

[0008] 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.

[0009] In some embodiments, the present disclosure relates to an aluminum alloy comprising from 0.20 wt. % to 1.30 wt. % Mg, from 0.30 wt. % to 1.40 wt. % Mn, up to 0.80 wt. % Fe, up to 0.60 wt. % Si, up to 0.30 wt. % Cu, up to 0.20 wt. % Cr, up to 0.40 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al; wherein the aluminum alloy comprises an area fraction of secondary phase particles between 1.4 % and 2.4 %, and wherein the aluminum alloy comprises 30 % or less of Alx(Fe,Mn)y type particles based on the total number of secondary phase particles. In some embodiments, the aluminum alloy comprises 50 % or greater recycled aluminum alloy materials. In some embodiments, the aluminum alloy comprises less than 20 wt. % prime aluminum. In some embodiments, the aluminum alloy has a yield strength of at least 200 MPa when in an H temper. In some embodiments, the aluminum alloy has an ultimateKT Ref. 108050-1523998tensile strength of at least 220 MPa when in an H temper. In some embodiments, the aluminum alloy has a total elongation of at least 3% when in an H temper. In some embodiments, the aluminum alloy exhibits a mean earing difference less than 2.0 % over a width of the aluminum alloy as measured according to DIN EN 1669 when measuring the mean earing at the center of the aluminum alloy and at the edge of the aluminum alloy. In some embodiments, the aluminum alloy shows no defect after 40mm length after being subjected to a bend and impact test using an Erichsen Bend and Impact Tester Model 471 according to the test procedure outlined in the Operating Instructions for the Bend and Impact Tester Model 471. In some embodiments, the aluminum alloy is subjected to an interannealing step. In some embodiments, the interannealing step comprises heating the aluminum alloy to a temperature from 250° C to 400° C and holding the aluminum alloy at the interannealing temperature for 4 or more hours. In some embodiments, a solvent based coating composition is disposed on the aluminum alloy. In some embodiments, a water based synthetic coating composition is disposed on the aluminum alloy. In some embodiments, the coating comprises one or more synthetic polymer binders, a crosslinker, and 1-40% dry weight of a polyamide. In some embodiments, the aluminum alloy comprises 0.30 wt. % to 1.20 wt. % Mg, from 0.30 wt. % to 1.30 wt. % Mn, up to 0.70 wt. % Fe, up to 0.50 wt. % Si, up to 0.25 wt. % Cu, up to 0.15 wt. % Cr, up to 0.30 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises 0.50 wt. % to 1.00 wt. % Mg, from 0.50 wt. % to 1.30 wt. % Mn, up to 0.60 wt. % Fe, up to 0.40 wt. % Si, up to 0.20 wt. % Cu, up to 0.10 wt. % Cr, up to 0.25 wt. % Zn, up to 0.05 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises 0.60 wt. % to 1.30 wt. % Mg, from 0.60 wt. % to 1.00 wt. % Mn, from 0.30 wt. % to 0.60 wt. % Fe, from 0.10 wt. % to 0.30 wt. % Si, from 0.10 wt. % to 0.25 wt. % Cu, up to 0.10 wt. % Cr, up to 0.20 wt. % Zn, up to 0.05 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.

[0010] In some embodiments, a slat for a garage door comprises the aluminum alloy described herein. In some embodiments, a slat for a roller shutter comprises the aluminum alloy described herein.

[0011] In some embodiments, the present disclosure provides a method of producing an aluminum alloy product comprising: casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises from 0.20 wt. % to 1.30 wt. % Mg, from 0.30 wt. % to 1.40 wt. % Mn, up to 0.80 wt. % Fe, up to 0.60 wt. % Si, up to 0.30 wt. % Cu, up to 0.20 wt. % Cr, upKT Ref. 108050-1523998to 0.40 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al, wherein the aluminum alloy comprises an area fraction of secondary phase particles between 1.4 % and 2.4 %, and wherein the aluminum alloy comprises 30 % or less of Alx(Fe,Mn)y type particles based on the total number of secondary phase particles; homogenizing the cast product; hot rolling the cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; optionally annealing during cold rolling. In some embodiments, casting the aluminum alloy comprises providing greater than 50 wt. % of recycled aluminum alloy materials to produce the cast product. In some embodiments, the method further comprises coating the final gauge rolled product. In some embodiments, the final gauge rolled product is used for a slat for a garage door or a roller shutter.

[0012] Further aspects, objects, and advantages will become apparent upon consideration of the detailed description and figures that follow.DETAILED DESCRIPTION

[0013] Described herein are 3xxx series aluminum alloys produced from recycled aluminum alloy materials that can replace existing aluminum alloys used for roller shutter and garage door applications. The 3xxx series aluminum alloys can be produced from predominantly recycled aluminum alloy materials (e.g., at least 50 %). The use of recycled aluminum alloy materials significantly reduces energy consumption and carbon emissions compared to conventional aluminum alloys used in roller shutter and garage door applications that include a high content of primary aluminum. Primary aluminum is the principal contributor to carbon emissions and recycled aluminum scrap can reduce up to 95% of the energy costs when compared to mining and extracting primary aluminum from bauxite. The 3xxx series aluminum alloys described herein provide an environmentally-friendly replacement for existing aluminum alloys used for roller shutter and garage door applications, while maintaining the required strength and improving the bending properties for further processing of the aluminum alloy product. Despite including high amounts of recycled aluminum alloy materials, the 3xxx series aluminum alloys described herein exhibit equivalent or better strength, elongation, earing, and bendability than conventional AA5006 aluminum alloys.

[0014] Conventional AA5006 aluminum alloy used for roller shutter and garage door applications include high amounts of primary aluminum. The high primary aluminum content leads to higher energy consumption and carbon emissions compared to an aluminum alloy produced from recycled aluminum materials. Although the use of recycled aluminum alloyKT Ref. 108050-1523998materials is an attractive proposition in that up to 95% of the energy costs can be saved when compared with the laborious extraction of the more costly primary aluminum, aluminum alloys produced from recycled aluminum materials result in a microstructure that may negatively affect properties such as formability. However, the aluminum alloys described herein surprisingly exhibits improved properties for earing behavior and bending compared to the current alloys used in the industry for slats for garage doors and roller shutter applications.

[0015] The 3xxx series aluminum alloys described herein exhibit the required strength and formability for slats for garage doors and roller shutters despite being produced from high amounts of recycled aluminum alloy materials and a distribution of secondary phases characteristic of such aluminum alloys. The aluminum alloys described herein incorporate higher amounts of recycled aluminum alloy materials and less primary aluminum, as compared to traditional AA5006 aluminum alloys, and still maintain good mechanical properties for use as garage doors and roller shutters, partly due to the unique microstruture of the aluminum alloy. For example, the aluminum alloys described herein may include more than 50% recycled aluminum alloy materials and less than 10% primary aluminum, and still exhibit properties similar to AA5006 aluminum alloys. The aluminum alloys described herein also provide a cost-effective alternative to the use of AA5006 aluminum alloys.Definitions and Descriptions

[0016] 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.

[0017] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “xxx .” 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.

[0018] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.KT Ref. 108050-1523998

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] As used herein, primary aluminum refers to an aluminum material including about at least 99.7 wt. % aluminum. Primary aluminum is produced from the prime transformation of raw material into aluminum (e.g., processing of bauxite into alumina and electrolysis of alumina into aluminum).

[0024] As used herein, yield stress (also referred to as yield strength) refers to the point at which an aluminum alloy begins to plastically deform and can no longer return to its original state.

[0025] 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 temperKT Ref. 108050-1523998refers to an aluminum alloy as fabricated. An 0 condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers.

[0026] 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.

[0027] 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.

[0028] 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.Recycle Content Alloys

[0029] Described below are 3xxx series aluminum alloys produced from a high content of recycled aluminum alloy materials. In certain aspects, the alloys exhibit the required strength and excellent formability. The properties of the alloys are achieved due to in part to the composition of the alloys and in part to the methods of processing the alloys to produce the described products (e.g., sheets).

[0030] The 3xxx series aluminum alloys described herein can tolerate higher amounts of recycled aluminum alloy materials and still exhibit desirable mechanical properties, thus making these alloys environmentally-friendly replacement for high prime content aluminum alloys. The impact of the impurities and / or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing a tailored aluminum alloy composition to compensate for the impurities and specific processing conditions. This enables a higher amount of less expensive, higher impurity recycled aluminum alloy materials for producing aluminum alloys that can still exhibit desirable properties. The aluminum alloy compositions describedKT Ref. 108050-1523998herein can include higher amounts of recycled aluminum alloy materials with little or no additional primary aluminum and a reduced amount of more expensive alloying elements.

[0031] In some embodiments, the aluminum alloy composition described herein provides a composition that is well-suited for utilizing multiple sources of recycled aluminum alloy materials. For example, the aluminum alloy can be a modifed AA3104 aluminum alloy or a AA3105 aluminum alloy that is produced from recycled aluminum alloy materials. In some embodiments, the recycled aluminum alloy materials scrap comprises Used Beverage Can (UBC scrap). The UBC scrap may comprise a portion or all of the recycled aluminum alloy materials used to produce the AA3104 aluminum alloy or the AA3105 aluminum alloy for slats for garage doors and roller shutters.

[0032] In other embodiments, the aluminum alloys described herein are produced from various scrap sources including mixed alloy scrap, unsegregated automotive scrap (e.g., containing one or more of 5xxx, 6xxx, and / or 7xxx series aluminum alloys from wrought and cast alloys), twitch, and recycled aluminum alloy parts (e.g., a heat exchanger, braze alloy scrap, etc.). The mixed alloy scrap is very low cost and using mixed alloy scrap to produce aluminum alloys can provide a significant cost reduction and reduce overall carbon emissions. As described herein, using these recycled aluminum alloy materials can achieve desirable mechanical properties, while using very low-cost recycled scrap.

[0033] In some aspects, the aluminum alloys described herein includes equal to or greater than 50 % recycled aluminum alloy materials, e.g., equal to or greater than 55 %, equal to or greater than 60 %, equal to or greater than 65 %, equal to or greater than 70 %, or equal to or greater than 75 %. In terms of ranges, the aluminum alloys described herein can include from 50 % to 95 % recycled aluminum alloy materials (e.g., from 50 % to 95 %, 55 % to 90 %, from 60 % to 85 %, from 65 % to 95 %, from 50 % to 70 %, or from 80 % to 90 %).

[0034] In some aspects, the recycled aluminum alloy materials includes equal to or greater than 50 % UBC scrap, e.g., equal to or greater than 55 %, equal to or greater than 60 %, equal to or greater than 65 %, equal to or greater than 70 %, or equal to or greater than 75 %. In terms of ranges, the aluminum alloys described herein can include from 50 % to 95 % UBC scrap (e.g., from 50 % to 95 %, 55 % to 90 %, from 60 % to 85 %, from 65 % to 95 %, from 50 % to 70 %, or from 80 % to 90 %).

[0035] In some aspects, the aluminum alloys described herein include less than 20 % primary aluminum, e.g., less than 19 %, less than 18 %, less than 17 %, less than 16 %, less than 15 %, less than 14 %, less than 13 %, less than 12 %, less than 11 %, or less than 10 %. All are expressed in wt. %.KT Ref. 108050-1523998Alloy Compositions

[0036] 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.

[0037] In some examples, an aluminum alloy as described herein can have the following elemental composition as provided in Table 1.Table 1

[0038] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 2.Table 2KT Ref. 108050-1523998

[0039] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 3.Table 3

[0040] In some examples, the aluminum alloy as described herein can have the following elemental composition as provided in Table 4.Table 4KT Ref. 108050-1523998Silicon (Si)

[0041] In some examples, the aluminum alloy described herein includes Si in an amount of up to 0.60% (e.g., up to 0.50%, up to 0.40%, from 0.01% to 0.50%, from 0.05% to 0.50%, or from 0.10% to 0.30%) 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%, or 0.60% Si. All expressed in wt.%.Iron (Fe)

[0042] In some examples, the aluminum alloy described herein also includes Fe in an amount up to 0.80% (e.g., up to 0.70%, up to 0.50%, from 0.01% to 0.50%, from 0.05% to 0.50%, or from 0.10% to 0.30%) 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%, or 0.80% Fe. All expressed in wt. %.Copper (Cu)

[0043] In some examples, the aluminum alloy described herein includes Cu in an amount n an amount up to 0.30% (e.g., up to 0.25%, up to 0.20%, from 0.01% to 0.30%, from 0.05% to 0.30%, or from 0.10% to 0.30%) 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%, or 0.30% Cu. All expressed in wt. %.KT Ref. 108050-1523998Manganese (Mn)

[0044] In some examples, the aluminum alloy described herein can include Mn in an amount from 0.30% to 1.40% (e.g., from 0.30% to 1.20%, from 0.40% to 1.20%, or from 0.50% to 1.00%) 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%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.00%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, or 1.40% Mn.Magnesium (Mg)

[0045] In some examples, the aluminum alloy described herein can include Mg in an amount from 0.20% to 1.30% (e.g., from 0.30% to 1.20%, from 0.40% to 1.20 %, or from 0.50% to 1.00%) 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%, 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%, or 1.30% Mg. All expressed in wt. %.Zinc (Zn)

[0046] In some examples, the aluminum alloy described herein can include Zn in an amount up to 0.40% (e.g., up to 0.30%, up to 0.20%, from 0.01% to 0.40%, from 0.05% to 0.30%, or from 0.10% to 0.40%) 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%,KT Ref. 108050-15239980.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, or 0.40% Zn. All expressed in wt. %.Titanium (Ti)

[0047] In some examples, the aluminum alloy described herein includes Ti in an amount up to 0.10% (e.g., up to 0.08%, up to 0.05%, from 0.01% to 0.10%, or from 0.01% to 0.05%) 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%, or 0.10% Ti. All expressed in wt. %.Chromium (Cr)

[0048] In some examples, the aluminum alloy described herein includes Cr in an amount up to 0.20% (e.g., up to 0.15%, up to 0.10%, from 0.01% to 0.20%, or from 0.05% to 0.15%) based on the total weight of the alloy. For example, the alloy can include 0.01%, 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% Cr. All expressed in wt.%.Aluminum Alloy Microstructure

[0049] The aluminum alloy microstructure of the aluminum alloys produced from recycled aluminum alloy materials has a strong influence on the resulting properties. It was found that by carefully controlling the composition and the methods of production can result in a high recycle content aluminum alloy that has the required strength and formability for slats in garage door and roller shutter applications. For example, an area fraction of secondary phases in the aluminum alloy microstructure is dependent on the chemical composition (e.g., the Fe and Si content) and is indicative of the formability properties of the aluminum alloy. The area fraction is calculated based on the area of secondary phases in the microstructure compared to the total area of the microstructure.

[0050] The secondary phases (also referred to as intermetallic constituents and / or Fe-containing particles) in the microstructure can be observed by optical microscopy or backscattered electron contrast in scanning electron microscopy (SEM) observation on a metallographically prepared sample and the area of secondary phase can be measured based on the images. For this, an image analysis by greyscale thresholding is used to detect the particles in the aluminum matrix. FIGs. 1A and IB show an example of an SEM image analysis using AZtec software from Oxford Instruments. The software provides automated feature analysis of particles using a backscattered electron image (FIG. 1A) to identify particles based on theirKT Ref. 108050-1523998grayscale levels. The software then automatically runs Energy Dispersive X-ray Spectroscopy (EDS) on each particle to determine its chemical composition (FIG. IB). The Aztec software classifies the particles using their morphological and elemental data and generates a report with a lookup table listing the parameters and results for each particle.

[0051] In some embodiments, the aluminum alloys described herein includes an area fraction of secondary phases from 1.4 % and 2.4 % (e.g., from 1.4 % and 2.4 %, from 1.4 % and 2.4 %, or from 1.4 % and 2.4 %). In some embodiments, the area fraction of secondary phases in the aluminum alloy microstructure is 1.4 %, 1.5 %, 1.6 %, 1.7 %, 1.8 %, 1.9 %, 2.0 %, 2.1 %, 2.2 %, 2.3 %, or 2.4 %.

[0052] The aluminum alloy compositions mentioned above include two predominant types of secondary phases. The first main type of secondary phase combines Al-Mn-Fe, in the following referred to as Alx(Fe,Mn)y phase. The second main type of secondary phase is Al-Mn-Fe-Si, in the following referred to as alpha phase. These unavoidable secondary phases influence both the evolution of the microstructure during the production processes, effect particle stimulated nucleation of grains during recrystallization as described in the literature [e.g., F.J. Humphreys and M. Hatherly, Recrystallization and Related Annealing Phenomena], and performance of the material in service or in downstream processing as secondary phases are also known to affect fracture behavior [e.g., H. L. Ewalds, R. J. H. Wanhill, Fracture Mechanics], Other secondary phases may be present in these alloys but have a limited influence on the properties.

[0053] In some examples, one or more alloying elements present in the aluminum alloy can combine with other elements to form intermetallic particles. For example, Fe can combine with Mn and Si to form alpha phase intermetallic particles and / or beta phase intermetallic particles. In some cases, it may be desirable to control the amounts of different intermetallic particles, or the ratio of different intermetallic particle amounts in an aluminum alloy or a metal product comprising the aluminum alloy. For example, in some cases, the aluminum alloy, a metal product made from or comprising the aluminum alloy, comprises 30 % or less of Alx(Fe,Mn)ytype particles, e.g., 25 % or less, 20 % or less, 15 % or less, or 10 % or less.

[0054] Different type of phases exhibit a range of shapes which are known to affect their evolution of size and shape during the rolling process [e.g., N. Moulin, D. Jeulin, H. Klbcker, Stress concentrations in non-convex elastic particles embedded in a ductile matrix, International Journal of Engineering Science, Volume 47, Issue 2, 2009, Pages 170-191],KT Ref. 108050-1523998Therefore, the phase type is an important factor affecting the final particle size distribution and their impact on properties of the aluminum alloy.Properties

[0055] In some examples, an aluminum alloy product (e.g., an aluminum alloy sheet) produced from the aluminum alloys described herein can have a yield strength (0.2% proof stress) of 200 MPa or greater when in a H temper (e.g., H44, H46, or H48 temper) and after coating at elevated temperatures. For example, an aluminum alloy product produced from the aluminum alloys described herein can have a yield strength of 205 MPa or greater, 210 MPa or greater, 215 MPa or greater, 220 MPa or greater, 225 MPa or greater, 230 MPa or greater, 235 MPa or greater, 240 MPa or greater, 245 MPa or greater, or 250 MPa or greater. In some cases, the yield strength is from 200 MPa to 250 MPa (e.g., from 205 MPa to 250 MPa, from 210 MPa to 240 MPa, or from 215 MPa to 240 MPa), or anywhere in between. 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 an ultimate tensile strength (UTS) of about 220 MPa or greater when in a (e.g., H44, H46, or H48 temper) temper and after coating at elevated temperatures. For example, the aluminum alloy products can have an ultimate tensile strength of 220 MPa or greater, 230 MPa or greater, 240 MPa or greater, 250 MPa or greater, 260 MPa or greater, 270 MPa or greater, 280 MPa or greater, 290 MPa or greater, or 300 MPa or greater. In some cases, the ultimate tensile strength is from 200 MPa to 400 MPa (e.g., from 220 MPa to 380 MPa, from 240 MPa to 360 MPa, or from 250 MPa to 340 MPa), or anywhere in between. The aluminum alloy products described herein can exhibit the ultimate tensile strengths as described herein when measured in a longitudinal (L) direction, a transverse (T) direction, and / or in a diagonal (D) direction, each respective to the rolling direction.

[0057] In some examples, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation (A50) from 3% to 10% when in a H temper and after coating at elevated temperatures (e.g., from 3% to 8%, from 3.3 % to 7%, from 3.5% to 7%, from 3.7% to 6%, or from 3.5% to 5.5%). For example, an aluminum alloy product produced from the aluminum alloys described herein can have a total elongation of about 3 %, 3.5 %, 4 %, 4.5 %, 5 %, 5.5 %, 6 %, 6.5 %, 7 %, 7.5 %, 8 %, 8.5 %, 9 %, 9.5 %, or 10 %, or anywhere in between. The aluminum alloy products described herein can exhibit the totalKT Ref. 108050-1523998elongations 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] The aluminum alloys described herein exhibit less variability across the width of the aluminum alloy than conventional aluminum alloys (e.g., AA5006 aluminum alloy). In most cases, properties of an aluminum alloy sheet vary in the sheet width direction. Therefore, even if earing of the aluminum alloy sheet is low on an average, a level of the earing may vary between the positions in the sheet width direction. If such variations in earing occur, the aluminum alloy may be more susceptible to failure. Beneficially, the aluminum alloys described herein exhibit low earing variation across the width of the aluminum alloy when subjected to cup drawings tests according to DIN EN 1669. The earing variation is determined by the difference of the earing values measured at the center of the aluminum alloy sheet and the edge of the aluminum alloy sheet. In some embodiments, an aluminum alloy product produced from the aluminum alloys described herein has a mean earing difference below 2.5 % over the width of the aluminum alloy as measured according to DIN EN 1669 when measuring the mean earing at the center of the aluminum alloy and at the edge of the aluminum alloy (e.g., less than 2.4 %, less than 2.4 %, less than 2.3 %, less than 2.2 %, less than 2.1 %, less than 2.0 %, less than 1.9 %, less than 1.8 %, less than 1.7 %, less than 1.6 %, or less than 1.5 %. In some embodiments, an aluminum alloy product produced from the aluminum alloys described herein has a mean earing difference from 0.1 % to 2.5 % over the width of the aluminum alloy as measured according to DIN EN 1669 when measuring the mean earing at the center of the aluminum and at the edge of the aluminum alloy (e.g., from 0.1 % to 2.5 %, from 0.1 % to 2.0 %, from 0.1 % to 1.5 %, from 0.1 % to 1.0 %, or from 0.2 % to 0.5 %)Methods of Making Aluminum Alloys

[0059] The aluminum alloys described herein can be cast into a cast product using a direct chill (DC) process or can be cast using a continuous casting (CC) process. The casting process is performed according to standards commonly used in the aluminum industry as known to one of skill in the art. The CC process may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters. In some examples, the casting process is performed by a CC process to form a slab, a strip, or the like. In some examples, the casting process is a DC casting process to form a cast product.

[0060] 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, aKT Ref. 108050-1523998homogenization step, a hot rolling step, and a cold rolling 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.

[0061] In a homogenization step, a cast product may be heated to a homogenization temperature, such as a temperature ranging from about 400 °C to about 610 °C. For example, the cast product can be heated to a temperature of 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, 460 °C, 470 °C, 480 °C, 490 °C, 500 °C, 510 °C, 520 °C, 530 °C, 540 °C, 550 °C, 560 °C, 570 °C, 580 °C, 590 °C, 600 °C, or 610 °C. In some embodiments, the heating rate to the peak metal temperature can be about 70 °C / hour or less, about 60 °C / hour or less, or about 50 °C / hour or less. 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 about 10 hours.

[0062] Following a homogenization step, a hot rolling step can be performed. The homogenized product can be hot rolled using a rolling mill to produce a hot rolled product. Prior to the start of hot rolling, the homogenized product can be allowed to cool to a desired temperature, such as from about 400 °C to about 550 °C. For example, the homogenized product can be allowed to cool to a temperature of from about 400 °C to about 525 °C, about 450 °C to about 525 °C, or from about 475 °C to about 525 °C. The homogenized product can then be hot rolled at a hot rolling temperature, for example, from about 200 °C to about 450 °C, to produce a hot rolled product (e.g., a hot rolled plate, a hot rolled shate, or a hot rolled sheet).

[0063] 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 about 0.5 to about 10 mm, e.g., between about 0.7 to about 6.5 mm. Optionally, the final gauge rolled product can have a gauge of about 0.5 mm, about 1.0 mm, about 1.5 mm, about 2.0 mm, about 2.5 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, about 5.0 mm, about 5.5 mm, about 6.0 mm, about 6.5 mm, about 7.0 mm, about 7.5 mm, about 8.0 mm, about 8.5 mm, about 9.0 mm, about 9.5 mm, or about 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) 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 thicknessKT Ref. 108050-1523998reduction. Optionally, the process for producing the aluminum alloy can include an interannealing step (e.g., between one or more cold rolling steps). The final gauge rolled product can be subjected to aging processes. For example, the final gauge rolled product can be provided in a H-temper (e.g., an Hl 9 temper).

[0064] In some embodiments, the cold rolled product can subjected to cleaning, pretreating, coating, and curing processes.

[0065] In some embodiments, the final gauge rolled product includes a polyamide-containing water-based, synthetic polymer coating or solvent based polymer coating composition. Some examples of the synthetic polymer binders suitable for the water-based synthetic polymer coating compositions are polyurethanes, polyesters and acrylics. The coating compositions is suitable for coating of metal substrates, such as aluminum panels and surfaces. The coating compositions form a coating with various advantageous properties, such as flexibility, adhesion, resistance to abrasion, and resistance to dust and other environmental influences, for example, ultraviolet radiation.Methods of Using Aluminum Alloys

[0066] The aluminum alloys described herein can each be used to produce large movable panels, garage doors, roller shutters, automotive applications and other transportation applications, including aircraft and railway applications. For example, the aluminum alloys can be used to prepare structural and non- structural parts for automotive and aerospace applications.

[0067] The aluminum alloys described herein can be used to make aluminum alloy products in the form of plates, extrusions, castings, and forgings or other suitable products. The products can be made using techniques as known to those of ordinary skill in the art. In some examples, the aluminum alloys can be used to produce extrusions. For example, the aluminum alloys described herein can be used to produce extruded aluminum alloy products.Illustrations

[0068] As used below, any reference to a series of illustrations is to be understood as a reference to each of those illustrations disjunctively (e.g., "Illustration 1-4" is to be understood as "Illustrations 1, 2, 3, or 4").

[0069] Illustration 1 is an alloy comprising from 0.20 wt. % to 1.30 wt. % Mg, from 0.30 wt. % to 1.40 wt. % Mn, up to 0.80 wt. % Fe, up to 0.60 wt. % Si, up to 0.30 wt. % Cu, up to 0.20 wt. % Cr, up to 0.40 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidableKT Ref. 108050-1523998impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al; wherein the aluminum alloy comprises an area fraction of secondary phase particles between 1.4 % and 2.4 %, and wherein the aluminum alloy comprises 30 % or less of Alx(Fe,Mn)y type particles based on the total number of secondary phase particles.

[0070] Illustration 2 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 50 % or greater recycled aluminum alloy materials.

[0071] Illustration 3 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises less than 20 wt. % prime aluminum.

[0072] Illustration 4 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has a yield strength of at least 200 MPa when in an H temper.

[0073] Illustration 5 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has an ultimate tensile strength of at least 220 MPa when in an H temper.

[0074] Illustration 6 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy has a total elongation of at least 3% when in an H temper.

[0075] Illustration 7 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy exhibits a mean earing difference less than 2.0 % over a width of the aluminum alloy as measured according to DIN EN 1669 when measuring the mean earing at the center of the aluminum alloy and at the edge of the aluminum alloy.

[0076] Illustration 8 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy is subjected to an interannealing step.

[0077] Illustration 9 is the aluminum alloy of any preceding or subsequent illustration, wherein the interannealing step comprises heating the aluminum alloy to a temperature from 250° C to 400° C and holding the aluminum alloy at the interannealing temperature for 4 or more hours.

[0078] Illustration 10 is the aluminum alloy of any preceding or subsequent illustration, wherein a solvent based coating composition is disposed on the aluminum alloy.

[0079] Illustration 11 is the aluminum alloy of any preceding or subsequent illustration, wherein a water based synthetic coating composition is disposed on the aluminum alloy.

[0080] Illustration 12 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.30 wt. % to 1.20 wt. % Mg, from 0.30 wt. % to 1.30 wt. % Mn, up to 0.70 wt. % Fe, up to 0.50 wt. % Si, up to 0.25 wt. % Cu, up to 0.15 wt. % Cr, up to 0.30 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.KT Ref. 108050-1523998

[0081] Illustration 13 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.50 wt. % to 1.00 wt. % Mg, from 0.50 wt. % to 1.30 wt. % Mn, up to 0.60 wt. % Fe, up to 0.40 wt. % Si, up to 0.20 wt. % Cu, up to 0.10 wt. % Cr, up to 0.25 wt. % Zn, up to 0.05 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.

[0082] Illustration 14 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.60 wt. % to 1.30 wt. % Mg, from 0.60 wt. % to 1.00 wt. % Mn, from 0.30 wt. % to 0.60 wt. % Fe, from 0.10 wt. % to 0.30 wt. % Si, from 0.10 wt. % to 0.25 wt. % Cu, up to 0.10 wt. % Cr, up to 0.20 wt. % Zn, up to 0.05 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.

[0083] Illustration 15 is a slat for a garage door comprising the aluminum alloy of any preceding or subsequent illustration.

[0084] Illustration 16 is a slat for a roller shutter comprising the aluminum alloy of any preceding or subsequent illustration.

[0085] Illustration 17 is a method of producing an aluminum alloy comprising: casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises from 0.20 wt. % to 1.30 wt. % Mg, from 0.30 wt. % to 1.40 wt. % Mn, up to 0.80 wt. % Fe, up to 0.60 wt. % Si, up to 0.30 wt. % Cu, up to 0.20 wt. % Cr, up to 0.40 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al, wherein the aluminum alloy comprises an area fraction of secondary phase particles between 1.4 % and 2.4 %, and wherein the aluminum alloy comprises 30 % or less of Alx(Fe,Mn)y type particles based on the total number of secondary phase particles; homogenizing the cast product; cold rolling the hot rolled product to produce a final gauge rolled product; hot rolling the cast product to produce a hot rolled product; optionally annealing during cold rolling.

[0086] Illustration 18 is the method of any preceding or subsequent illustration, wherein casting the aluminum alloy comprises providing greater than 50 wt. % of recycled aluminum alloy materials to produce the cast product..

[0087] Illustration 19 is the method of any preceding or subsequent illustration, further comprising coating the final gauge rolled product.

[0088] Illustration 20 is the method of any preceding or subsequent illustration, wherein the final gauge rolled product is used for a slat for a garage door or a roller shutter.KT Ref. 108050-1523998

[0089] The following examples will serve to further illustrate the present invention without, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention.

[0090] During the studies described in the following examples, conventional procedures were followed, unless otherwise stated. Some of the procedures are described below for illustrative purposes.Examples

[0091] Sample aluminum alloy products were tested to determine the properties of the high recycle content aluminum alloys described herein. The aluminum alloys were direct chill cast, homogenized, hot rolled, cold rolled, and coated to produce the aluminum alloy products. The aluminum alloys were interannealed between cold rolling steps to provide the aluminum alloy products in an H44 temper. Example 1 is a AA3104 aluminum alloy and Example 2 is a AA3105 aluminum alloy. Comparative Alloy A is a AA5006 aluminum alloy. Table 5 provides the composition for Examples 1 and 2 and Comparative Alloy A. Table 6 provides the typical maximum prime share for each of Comparative Example A and Example Alloys 1 and 2.TABLE 5TABLE 6KT Ref. 108050-1523998

[0092] As shown in Table 6, Examples 1 and 2 have less prime content that Comparative Example A. Example 1 which is AA3104 aluminum alloy, was produced from less than 10 % prime aluminum, whereas Comparative Example A, which is a AA5006 aluminum alloy, was produced from about 90 % prime aluminum. Therefore, Examples 1 and 2 can be used as an environmentally friendly replacement of AA5006 aluminum alloy.

[0093] Table 7 provides the yield strength, ultimate tensile strength (UTS), and elongation of Examples 1 and 2 and Comparative Example A, after being subjected to various process conditions. Each of the alloys exhibited a yield strength above 200 MPa and an UTS above 220 MPa, while the elongation was above 3%. The data demonstrates that recycle friendly alloys of Examples 1 and 2 can be an effective replacement for AA5006 aluminum alloy for slats for roller shutters and garage doors that meet the requisite strength and formability requirements for such applications.Table 7

[0001] Table 8 provides the mean earing and variation of earing for Examples 1 and 2 when measured across the width of the aluminum alloy products. Cup drawings tests were performed according to DIN EN 1669. Both Examples 1 and 2 exhibited significantly lower variation across the width of the aluminum alloy product than Comparative Alloy A. This demonstrates that Examples 1 and 2 have a more uniform formability than AA5006 alloy, and are suitable for forming and shaping processes.Table 8KT Ref. 108050-1523998

[0002] Example 1 and 2 and Comparative Example A were subjected to bend tests. Each of the alloy products were coated with anthracite prior to bend testing. The alloys were subjected to bend tests using an Erichsen Bend and Impact Tester Model 471 according to the test procedure outlined in the Operating Instructions for the Bend and Impact Tester Model 471. Table 9 provides the length of identified damage on the radius of the material after the bend and impact test and after additional heat treatment of 30 minutes at 80 °C was performed (simulating processing conditions) and before Cupper Sulfate evaluation. As shown in Table 9, Examples 1 and 2 each exhibited better bending results than Comparative Example A.Table 9

[0003] Table 10 provides a measurement of the area fraction (%) of secondary phases in Examples 1 and 2 and Comparative Example A. Table 11 provides a measurement of the phase fraction (%) in Examples 1 and 2 and Comparative Example A. A microstructural analysis was performed to determine the fraction and phase of intermetallic constituents and / or Fe-containing particles in the microstructure of Examples 1 and 2 and Comparative Example A. The fraction and phase of intermetallic constituents and / or Fe-containing particles in the microstructure was determined by scanning electron microscopy observation on a metallographically prepared cross section sample of the alloys from the longitudinal plane. An automated image analysis by greyscale thresholding was used to detect the particles in the aluminum matrix and their chemical composition was measured with the commercially available software from AZtec provided by Oxford Instruments. FIGs. 2A-2C show example images from the three alloys with a backscattered electron image (top image) and the automatic particle detection result (bottom image). Phase classification was performed by differentiating the Si content, measured by energy-dispersive X-ray microanalysis (EDX), in the identified particles to give two particle categories: (1) Alx(Fe,Mn)y; and (2) Al-Fe-Mn particles containing Si, referred to in the following as alpha particles.KT Ref. 108050-1523998Table 10.Table 11.

[0004] The area fraction of secondary phase in Examples 1 and 2 was significantly higher than the area fraction of secondary phase in Comparative Alloy A. Additionally, Examples 1 and 2 included a lower amount of Alx(Fe,Mn)y phase (e.g., 0.30 or less) than Comparative Alloy A. Surprisingly, the microstructure of the alloys of Examples 1 and 2 having the aforementioned amounts of secondary phase and alpha / Alx(Fe,Mn)y phase ratio results in better formability than conventional AA5006 aluminum alloy. The secondary phases influence fracture behavior in the aluminum through the formation of voids around these particles. Therefore, it is unexpected and surprising that at a similar level of strength, Examples 1 and 2 exhibit better formability such as bending. The type of phases and ratio is also an important factor to obtain a particular size distribution of particles which will in turn impact the mechanical behavior of the sheet material.

[0094] 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.

Claims

KT Ref. 108050-1523998WHAT IS CLAIMED IS:

1. An aluminum alloy comprising from 0.20 wt. % to 1.30 wt. % Mg, from 0.30 wt. % to 1.40 wt. % Mn, up to 0.80 wt. % Fe, up to 0.60 wt. % Si, up to 0.30 wt. % Cu, up to 0.20 wt. % Cr, up to 0.40 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al;wherein the aluminum alloy comprises an area fraction of secondary phase particles between 1.4 % and 2.4 %, and wherein the aluminum alloy comprises 30 % or less of Alx(Fe,Mn)ytype particles based on the total number of secondary phase particles.

2. The aluminum alloy of claim 1, wherein the aluminum alloy comprises 50 % or greater recycled aluminum alloy materials.

3. The aluminum alloy of claim 1, wherein the aluminum alloy comprises less than 20 wt. % prime aluminum.

4. The aluminum alloy of claim 1, wherein the aluminum alloy has a yield strength of at least 200 MPa when in an H temper.

5. The aluminum alloy of claim 1, wherein the aluminum alloy has an ultimate tensile strength of at least 220 MPa when in an H temper.

6. The aluminum alloy of claim 1, wherein the aluminum alloy has a total elongation of at least 3% when in an H temper.

7. The aluminum alloy of claim 1, wherein the aluminum alloy exhibits a mean earing difference less than 2.0 % over a width of the aluminum alloy as measured according to DIN EN 1669 when measuring the mean earing at the center of the aluminum alloy and at the edge of the aluminum alloy.

8. The aluminum alloy of claim 1, wherein the aluminum alloy is subjected to an interannealing step.

9. The aluminum alloy of claim 8, wherein the interannealing step comprises heating the aluminum alloy to a temperature from 250° C to 400° C and holding the aluminum alloy at the interannealing temperature for 4 or more hours.KT Ref. 108050-152399810. The aluminum alloy of claim 1, wherein a solvent based coating composition is disposed on the aluminum alloy.

11. The aluminum alloy of claim 1, wherein a water based synthetic coating composition is disposed on the aluminum alloy.

12. The aluminum alloy of claim 1, wherein the aluminum alloy comprises 0.30 wt. % to 1.20 wt. % Mg, from 0.30 wt. % to 1.30 wt. % Mn, up to 0.70 wt. % Fe, up to 0.50 wt. % Si, up to 0.25 wt. % Cu, up to 0.15 wt. % Cr, up to 0.30 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.

13. The aluminum alloy of claim 1, wherein the aluminum alloy comprises0.50 wt. % to 1.00 wt. % Mg, from 0.50 wt. % to 1.30 wt. % Mn, up to 0.60 wt. % Fe, up to 0.40 wt. % Si, up to 0.20 wt. % Cu, up to 0.10 wt. % Cr, up to 0.25 wt. % Zn, up to 0.05 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.

14. The aluminum alloy of claim 1, wherein the aluminum alloy comprises0.60 wt. % to 1.30 wt. % Mg, from 0.60 wt. % to 1.00 wt. % Mn, from 0.30 wt. % to 0.60 wt. % Fe, from 0.10 wt. % to 0.30 wt. % Si, from 0.10 wt. % to 0.25 wt. % Cu, up to 0.10 wt. % Cr, up to 0.20 wt. % Zn, up to 0.05 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al.

15. A slat for a garage door comprising the aluminum alloy of claim 1.

16. A slat for a roller shutter comprising the aluminum alloy of claim 1.

17. A method of producing an aluminum alloy comprising:casting an aluminum alloy to form a cast product, wherein the aluminum alloy comprises from 0.20 wt. % to 1.30 wt. % Mg, from 0.30 wt. % to 1.40 wt. % Mn, up to 0.80 wt. % Fe, up to 0.60 wt. % Si, up to 0.30 wt. % Cu, up to 0.20 wt. % Cr, up to 0.40 wt. % Zn, up to 0.10 wt. % Ti, up to 0.05 wt. % unavoidable impurities, up to 0.15 wt. % total unavoidable impurities, and the remainder Al, wherein the aluminum alloy comprises an area fraction of secondary phase particles between 1.4 % and 2.4 %, and wherein the aluminumKT Ref. 108050-1523998alloy comprises 30 % or less of Alx(Fe,Mn)ytype particles based on the total number of secondary phase particles;homogenizing the cast product;hot rolling the cast product to produce a hot rolled product;cold rolling the hot rolled product to produce a final gauge rolled product; optionally annealing during cold rolling.

18. The method of claim 17, wherein casting the aluminum alloy comprises providing greater than 50 wt. % of recycled aluminum alloy materials to produce the cast product.

19. The method of claim 18, further comprising coating the final gauge rolled product.

20. The method of claim 17, wherein the final gauge rolled product is used for a slat for a garage door or a roller shutter.

Images