Direct chill cast 3xxx series aluminum alloy with improved electrical and thermal conductivity

Abstract

Provided are aluminum 3xxx series alloy products having improved thermal and electrical stability, and methods for forming such products. Methods include DC casting a molten aluminum alloy, withdrawing the aluminum alloy from the mold to form an ingot, homogenizing the ingot at a homogenization temperature from 500 °C to 650 °C for a period of time from 1 to 5 hours. Methods include reducing the temperature to a soaking temperature from 350 °C to 550 °C and soaking the ingot for a period of time from 1 to 15 hours. Methods include hot rolling the homogenized ingot to produce a hot rolled aluminum alloy, and cold rolling the hot rolled aluminum alloy to produce to an aluminum alloy product.

Description

PATENT Attorney Docket No. 108050-1523992DIRECT CHILL CAST 3XXX SERIES ALUMINUM ALLOY WITH ELECTRICAL AND THERMAL CONDUCTIVITYCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 719,944, filed November 13, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes.TECHNICAL FIELD

[0002] This present disclosure relates to the fields of material science, material chemistry, metallurgy, aluminum alloys, aluminum fabrication, and related fields. In particular, the present disclosure provides treatments for 3xxx series aluminum alloys suitable for direct chill casting and that exhibit excellent thermal conductivity. The disclosure also provides direct chill casting methods for producing and processing 3xxx series aluminum alloy products.BACKGROUND

[0003] Direct chill (DC) and continuous casting are two methods of casting solid metal from liquid metal. In continuous casting, molten metal is injected into a casting cavity between two moving opposed casting surfaces and withdrawn as a cast metal form from the exit of the casting cavity. Continuous casting has been desirable in some instances where an entire product can be prepared in a single, fully-couple processing line or a decouple processing line. Continuous casting is capable of casting solid metal at faster rates, lower energy usages, and at lower cost. Continuous cast aluminums have also shown good electrical and thermal conductivity using recycled material. Methods of continuous casting 3xxx series aluminum using recycled aluminum have previously been developed. However, continuous casting continues to afford less microstructure control compared to DC cast alloys, and may exhibit lower surface finish. In addition, alloy elements in continuous cast products tend to concentrate in the middle of the cast product resulting in loss of homogeneity compared to DC cast products.

[0004] In DC casting, liquid metal is poured into a mold having a retractable false bottom capable of withdrawing at the rate of solidification of the liquid metal in the mold, often resulting in a large and relatively thick ingot (e.g., 1500 mm x 500 mm x 5 m). The ingot canPATENT Attorney Docket No. 108050-1523992be processed, homogenized, hot rolled, cold rolled, annealed and / or heat treated, and otherwise finished before being shaped into a product distributable to a consumer of the metal product. Traditionally, DC cast 3xxx series aluminum has not had the necessary properties for use in applications requiring higher thermal and / or electrical conductivity. Therefore, there is a need in the art to improve the thermal and electrical conductivity of DC 3xxx series cast aluminum. Furthermore, there is a need in the art to improve the thermal and electrical conductivity of 3xxx series alloys that incorporate recycled aluminum.BRIEF SUMMARY

[0005] The present technology is generally directed to methods of direct chill casting aluminum alloy products. Methods include casting an aluminum alloy in a mold, where the aluminum alloy includes, 0.40 - 1.30 wt. % Si, 0.50 - 2.50 wt. % Fe, 0.10 - 0.40 wt. % Cu, up to 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. Methods include withdrawing the aluminum alloy from the mold to form an ingot and homogenizing the ingot at a homogenization temperature from 500 °C to 650 °C for a period of time from 1 to 5 hours, and reducing the temperature to a soaking temperature from 350 °C to 550 °C and soaking the ingot for a period of time from 1 to 15 hours. Methods include hot rolling the homogenized ingot to produce a hot rolled aluminum alloy and cold rolling the hot rolled aluminum alloy to produce to an aluminum alloy product.

[0006] In embodiments, the soaking temperature include a temperature from 350 °C to 450 °C. Moreover, in embodiments, the direct chill cast aluminum alloy is subjected to soaking for a period of 5 to 15 hours. In further embodiments, methods include annealing the hot rolled aluminum alloy. Additionally or alternatively, in embodiments, the annealing includes an annealing temperature from 300 °C to 450 °C for a period of time from 3 to 10 hours. Embodiments include where the annealing is a ramped annealing at a heating rate of at least 10° C / h for a period of time from 1 to 5 hours. In embodiments, methods include tempering the aluminum alloy product. Furthermore, in embodiments, the cold rolling reduces a thickness of the aluminum alloy product by greater than or about 75% of a thickness of the aluminum alloy product after one or more hot rolling operations. In more embodiments, the aluminum alloy is a 3xxx series aluminum alloy. In yet more embodiments, the aluminum alloy includes at least about 40 wt.% recycled content. Embodiments includePATENT Attorney Docket No. 108050-1523992where the aluminum alloy product has a thermal conductivity greater than or about 180 W / (m*K).

[0007] The present technology is also generally directed to fin stocks prepared according to any one or more of the above embodiments.

[0008] The present technology is also generally directed to direct chill cast aluminum alloy products. Products include 0.40 - 1.30 wt. % Si, 0.50 - 2.50 wt. % Fe, 0.10 - 0.40 wt. % Cu, up to 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. Products include where the direct chill cast aluminum alloy product comprises an electrical conductivity from 40 % to 60 % based on the international annealed copper standard (IACS) and a percent elongation of 1 % to 15 % according to ASTM E8ZE8M-22 testing standards.

[0009] In embodiments, the direct chill cast aluminum alloy product includes alpha phase particles and an aluminum alloy matrix, where the aluminum alloy matrix comprises less than 0.1 wt.% Mn. Furthermore in embodiments, the direct chill cast aluminum alloy product includes less than 0.1 wt.% Cr. In more embodiments, the direct chill cast aluminum alloy product includes a combined content of Si and Fe of at least 1.50 wt. %, and the aluminum alloy product includes a ratio of (Si + Fe): Mn of at least 2.0:1. Embodiments include where the direct chill cast aluminum alloy product has a yield strength greater than or about 60 MPa. Additionally or alternatively, in embodiments, the direct chill cast aluminum alloy product includes an ultimate tensile strength greater than or about 130 MPa. In yet more embodiments, the direct chill cast aluminum alloy product has a thermal conductivity greater than 180 W / (m*K).

[0010] The present technology also include fin stocks formed from the direct chill cast aluminum alloy product or method of any one or more of the embodiments discussed herein.

[0011] Various implementations described herein may include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIGS. 1-6 show graphs of tested properties, according to examples of the present technology.PATENT Attorney Docket No. 108050-1523992DETAILED DESCRIPTION

[0013] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure 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 claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure 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 of this disclosure, any or all drawings and each claim.

[0014] Disclosed herein are methods, including one or more homogenization or annealing operations, for forming one or more DC cast 3xxx series aluminum alloys and products thereof. In embodiments, the one or more homogenization operations may form DC cast 3xxx series aluminum alloys which are well suited for applications requiring high thermal and electrical conductivity. Namely, the present technology has surprisingly found that by carefully tailoring the one or more homogenization operations, an amount of solute contents in the aluminum matrix may be reduced, allowing for improved thermal and electrical properties in alloys previously believed to be unsuitable for such applications. For instance, in embodiments, the present technology may provide methods for forming DC cast 3xxx aluminum alloys that allow for the formation of a higher amount of particles, allowing for higher thermal and electrical conductivity in the aluminum matrix. In addition, due to the formation of the high amount of particles, the 3xxx series aluminum alloys discussed herein are also well suited for utilizing a high recycled content in the starting liquid metal while exhibiting such favorable properties. Namely, the 3xxx series aluminum alloys discussed herein can be formed utilizing a DC casting processes, and yield aluminum alloy products having high electrical and thermal conductivity relative to other 3xxx series aluminum alloys, even with high weight percentages of alloying elements, while maintaining favorable mechanical properties such as ultimate yield strength and formability.

[0015] For instance, a traditionally processed 3105 series aluminum alloy exhibits a thermal conductivity of approximately 131.0 W / m*K. Conversely, alloys suitable for use in applications requiring thermal and / or electrical conductivity (one example of which may bePATENT Attorney Docket No. 108050-1523992fin stock for heat exchange products), such as a 7072 series aluminum alloy, typically exhibit a thermal conductivity around 237.0 W / m*K. Surprisingly, by utilizing the methods discussed herein, a 3xxx series aluminum alloy may be modified to have a thermal conductivity similar (e.g., within 70%, 80%, 90%, or even 100%) to a thermal conductivity of a substantially pure 7xxx series aluminum alloy, for example, a 7072 aluminum alloy. Thus, DC cast 3xxx series aluminum alloys according to the present technology may be utilized in applications requiring higher thermal or electrical conductivity. As discussed above, without wishing to be bound by theory, it is believed that solute content may be reduced in an alloy matrix by precipitating secondary phase particles such as dispersoids. In 3xxx series aluminum, two types of phases form during solidification, an alpha phase Ali2(Fe,Mn)3Si and a beta phase Ale(Fe,Mn). By utilizing high-Si and high-Fe scrap 3xxx series aluminum in conjunction with methods provided herein utilizing one or more homogenization operations, to form a DC cast aluminum alloy, solutes may be precipitated out of the alloy matrix and into alpha phases in order to increase the electrical and thermal conductivity of an aluminum alloy product. In embodiments, little to no beta phase dispersoids may be observed in the compositions discussed herein. Moreover, the relative increase in silicon and iron, such as from recycled content may improve the mechanical and thermal properties of the aluminum alloy product.Definitions and Descriptions:

[0016] The terms “invention,” “the invention,” “this invention,” and “the present invention” used herein are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0017] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “3xxx .” 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.PATENT Attorney Docket No. 108050-1523992

[0018] The following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %, or %) based on the total weight of the alloy. In certain examples of each alloy, the remainder of the composition is aluminum, with a maximum wt. % of 0.15 % for the sum of the impurities. The wt.% of the aluminum alloys adds up to 100 wt.% total and may include Al in an amount to total to 100 wt.%.

[0019] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0020] As used herein, a plate generally has a thickness of greater than 15 mm up to 200 mm. For example, a plate may refer to an aluminum alloy product having a thickness of greater than 15 mm, greater than 20 mm, greater than 25 mm, greater than 30 mm, greater than 35 mm, greater than 40 mm, greater than 45 mm, greater than 50 mm, greater than 100 mm, or up to 200 mm.

[0021] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from 4 mm to 15 mm. For example, a shate may have a thickness of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.

[0022] As used herein, a sheet or a foil generally refers to an aluminum product having a thickness of less than 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 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5, 0.6 mm 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm 2.7 mm, 2.8 mm, 2.9 mm, 3 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, or 4 mm.

[0023] 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.

[0024] Reference may be made in this application to ASTM E8ZE8M-22 standard testing. The ASTM E8ZE8M-22 standard is established by ASTM International and is a widely recognized set of guidelines for conducting tension testing of metallic materials. The ASTM E8ZE8M-22 standard provides detailed procedures and requirements for performing tension tests on metallic materials to determine their tensile properties. This includes the determination of yield strength, tensile strength, elongation, and reduction of area. ThesePATENT Attorney Docket No. 108050-1523992properties are critical for understanding the behavior of metals under tensile loads, which is essential for various engineering and structural applications.

[0025] As used herein, the International Annealed Copper Standard (IACS) defines the electrical conductivity of pure, annealed copper as 100%. This standard serves as a reference point against which the conductivity of other materials can be measured and expressed as a percentage of the conductivity of annealed copper.

[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 aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A TI 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, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method. However, as discussed above, in aspects, the aluminum alloy products discussed herein may be cast utilizing DC casting methods.PATENT Attorney Docket No. 108050-1523992

[0028] As used herein, the meaning of “room temperature” can include a temperature of from 15 °C to 30 °C, for example 15 °C, 16 °C, 17 °C, 18 °C, 19 °C, 20 °C, 21 °C, 22 °C, 23 °C, 24 °C, 25 °C, 26 °C, 27 °C, 28 °C, 29 °C, or 30 °C.

[0029] All ranges disclosed herein are to be understood to encompass any 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.Alloy Compositions

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

[0031] The alloy and product described herein include aluminum compositions. The aluminum compositions exhibit desirable mechanical and physical properties, such as formability, strength, and a refined microstructure. The properties of the composition are achieved at least in part due to the elemental composition of the aluminum. In embodiments, at least a portion of the alloy composition includes recycled aluminum alloy content, which will be discussed in greater detail below.

[0032] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 1.Table 1PATENT Attorney Docket No. 108050-1523992

[0033] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 2.Table 2

[0034] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 3.Table 3PATENT Attorney Docket No. 108050-1523992

[0035] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 4.Table 4

[0036] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 5.Table 5PATENT Attorney Docket No. 108050-1523992Silicon (Si)

[0037] In some examples, the alloy includes silicon (Si) in an amount from 0.10 % to 1.30 % (e.g., from 0.20 % to 1.20 %, from 0.30 % to 1.10 %, from 0.60 % to 0.90 %, from 0.50 % to 1.00 %, from 0.60 % to 1.00 %, or from 0.80 % to 1.30 %) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 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 % Si. All percentages are expressed in wt. %. As described above, the Si content promotes formation of Mn-containing dispersoids to improve thermal conductivity of the aluminum alloy, thus producing alloys that have good thermal conductivity. Specifically, Si combines with Mn and results in a high density of alpha phase particles (e.g., Ali2(Fe,Mn)3Si) and / or beta phase particles (e.g., Ale(Fe,Mn)) in the aluminum alloy microstructure. The formation of alpha phase particles and beta phase particles takes free Mn out of solid solution during solidification (e.g., during casting) to reduce the negative effects of Mn on thermal conductivity. Additionally, homogenization or annealing can help pull out more Mn by growth of alpha particles and / or formation of alpha dispersoids which can further pull Mn out of solution.Iron (Fe)

[0038] In some examples, the alloy also iron (Fe) in an amount from 0.10 % to 1.00 % (e.g., from 0.20 % to 0.90 %, from 0.30 % to 0.90 %, from 0.50 % to 0.90 %, from 0.40 % to 0.90 %, or from 0.70 % to 1.00 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %,PATENT Attorney Docket No. 108050-15239920.19 %, 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 %, 0.68 %, 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 %, or 1.00 % Fe. All percentages are expressed in wt. %. In some instances, Fe and Si promotes formation of Mn-containing dispersoids to improve thermal conductivity of the aluminum alloy. As discussed above, Fe and Si can combine with Mn to produce a high density of alpha phase particles and / or beta phase particles to take free Mn out of solid solution during solidification (e.g., during casting) and after homogenization or annealing treatment to reduce the negative effects of Mn on thermal conductivity.Copper (Cu)

[0039] In some examples, the alloy includes copper (Cu) in an amount from 0 % to 0.30 % (e.g., from 0.01 % to 0.30 %, from 0.01 % to 0.25 %, from 0.01 % to 0.20 %, or from 0.10 % to 0.30 %) based on the total weight of the alloy. For example, the alloy can include 0 %, 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 percentages are expressed in wt. %. In some instances, a Cu content above 0.30 wt. % may lead to corrosion problems as it leads to positive corrosion potentials which is not desirable for fin stock materials.Manganese (Mn)

[0040] In some examples, the alloy includes manganese (Mn) in an amount from 0.01 % to 0.80% (e.g., from 0.05 % to 0.70 %, from 0.10 % to 0.70 %, from 0.20 % to 0.80 %, from 0.30 % to 0.70 %, or from 0.30 % to 0.50 %) 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 %, 0.63PATENT Attorney Docket No. 108050-1523992%, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, or 0.80 % Mn. All percentages are expressed in wt. %. As discussed above and shown in FIG. 1, Mn has largest negative impact on thermal conductivity. Mn largely remains in solid solution while a small amount is precipitated during solidification as constituents and as dispersoids during ingot pre-heating and annealing steps. The addition of Si and Fe in the amounts described herein promotes formation of Mn-containing dispersoids to limit the negative impact of Mn on thermal conductivity.Surprisingly, the aluminum alloys described herein can achieve a balance strength due to the solid solution strengthening effects of the Mn while limiting the negative impact of Mn on thermal conductivity. Sufficient Mn, (optionally, in combination with Cu), is added to the aluminum alloy to provide strength, sagging resistance, and avoid fin erosion, but not so much to adversely affect the thermal conductivity.Magnesium (Mg)

[0041] In some examples, the alloy included magnesium (Mg) in an amount from 0.20 % to 0.80% (e.g., from 0.20 % to 0.80 %, from 0.25 % to 0.80 %, or from 0.30 % to 0.80 %) 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 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, or 0.80 % Mg. All percentages are expressed in wt. %.Zinc (Zn)

[0042] In some examples, the alloy includes zinc (Zn) in an amount from 0.50 % to 3.50% (e.g., from 0.50 % to 3.25 %, from 0.60 % to 3.00 %, from 0.60 % to 2.75 %, from 0.50 % to 2.50 %, from 0.60 % to 2.25 %, or from 0.70 % to 2.00%) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 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 %, 1.20PATENT Attorney Docket No. 108050-1523992%, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %, 1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %, 1.44 %, 1.45 %, 1.46 %, 1.47 %, 1.48 %, 1.49 %, 1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %, 1.55 %, 1.56 %, 1.57 %, 1.58 %, 1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %, 1.66 %, 1.67 %, 1.68 %, 1.69 %, 1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %, 1.77 %, 1.78 %, 1.79 %, 1.80 %, 1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %, 1.88 %, 1.89 %, 1.90 %, 1.91 %, 1.92 %, 1.93 %, 1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %, 1.99 %, 2.00 %, 2.01 %, 2.02 %, 2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %, 2.10 %, 2.11 %, 2.12 %, 2.13 %, 2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %, 2.21 %, 2.22 %, 2.23 %, 2.24 %, 2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %, 2.32 %, 2.33 %, 2.34 %, 2.35 %, 2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %, 2.43 %, 2.44 %, 2.45 %, 2.46 %, 2.47 %, 2.48 %, 2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %, 2.54 %, 2.55 %, 2.56 %, 2.57 %, 2.58 %, 2.59 %, 2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %, 2.65 %, 2.66 %, 2.67 %, 2.68 %, 2.69 %, 2.70 %, 2.71 %, 2.72 %, 2.73 %, 2.74 %, 2.75 %, 2.76 %, 2.77 %, 2.78 %, 2.79 %, 2.80 %, 2.81 %, 2.82 %, 2.83 %, 2.84 %, 2.85 %, 2.86 %, 2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %, 2.92 %, 2.93 %, 2.94 %, 2.95 %, 2.96 %, 2.97 %, 2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %, 3.03 %, 3.04 %, 3.05 %, 3.06 %, 3.07 %, 3.08 %, 3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %, 3.14 %, 3.15 %, 3.16 %, 3.17 %, 3.18 %, 3.19 %, 3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %, 3.25 %, 3.26 %, 3.27 %, 3.28 %, 3.29 %, 3.30 %, 3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %, 3.36 %, 3.37 %, 3.38 %, 3.39 %, 3.40 %, 3.41 %, 3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %, 3.47 %, 3.48 %, 3.49 %, or 3.50 % Zn. All percentages are expressed in wt. %. The Zn content can improve the corrosion potential of the aluminum alloys described herein. Zn affects the anodic potential of aluminum alloys. Zn addition will cause an aluminum alloy to become more electronegative (sacrificial). In some embodiments, the Zn content of the aluminum alloys described herein is higher compared to AA3105 aluminum alloy such that the aluminum alloy will be able to act sacrificially when attached to copper or other aluminum alloy tubes, thus providing cathodic protection to the tubes. It is preferable in heat exchanger units that the fin material is sacrificial to the tube material and that will depend on the composition of the tube material itself. By using an aluminum alloy having sufficient Zn for fin stock, the difference in corrosion potential between the tubes and fin stock can be tailored for an adequate level of protection. Specifically, when Zn is incorporated at a level as described herein, such as from 0.50 % to 3.50 %, the alloys exhibit a more adequate corrosion potential as compared toPATENT Attorney Docket No. 108050-1523992AA3105 aluminum alloy. In still further examples, Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin. For example, at Zn levels higher than those described herein, the alloys for use as fins can corrode more rapidly than for fins containing the described amount of Zn, resulting in perforations in the fin. As a result, the mechanical integrity and thermal performance of the heat exchanger can be compromised, thus affecting the service life of the heat exchanger. In some embodiments, the aluminum alloy includes at least 1.30 wt. %, such as at least 1.40 wt. %, at least 1.50 wt. %, or at least 1.60 wt. % Zn to provide good corrosion potential.Chromium (Cr)

[0043] In some examples, the alloy includes chromium (Cr) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 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. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.Titanium (Ti)

[0044] In some examples, the alloy includes titanium (Ti) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 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 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.

[0045] Optionally, the alloy compositions 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 each. These impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, Sr, or combinations thereof. Accordingly, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below. In certain aspects, the sum of all impurities does not exceedPATENT Attorney Docket No. 108050-15239920.15 % (e.g., 0.1 %). All percentages are expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.

[0046] In some embodiments, the aluminum alloy comprises a combined content of Si and Fe of at least 0.50 % (e.g., at least 0.60 %, at least 0.70 %, at least 0.80 %, at least 0.90 %, at least 1.00 %, at least 1.10 %, at least 1.20%, at least 1.25 %, at least 1.30 %, at least 1.40 %, or at least 1.50 %). In some embodiments, the aluminum alloy comprises a combined content of Si and Fe from 0.50 % to 2.30 % (e.g., from 0.50 % to 1.80 %, from 0.60 % to 2.20 %, from 0.70 % to 2.10 %, from 0.80 % to 2.00 %, from 0.90 % to 1.80 %, from 1.00 % to 2.10 %, from 1.10 % to 2.20 %, from 1.20 % to 2.00 %, or from 1.70 % to 2.30 %). All percentages are expressed in wt. %.

[0047] In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90:1 (e.g., at least 1.00:1, at least 1.20:1, at least 1.40:1, at least 1.60:1, at least 1.80:1, at least 2.0:1, at least 2.20:1, at least 2.40:1, or at least 2.5:1). In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn from 0.90:1 to 3.00:1 (e.g., from 1.00:1 to 3.00:1, from 1.20:1 to 2.90:1, from 1.10:1 to 2.80:1, from 1.20:1 to 2.75:1, from 1.25:1 to 2.60:1, from 1.40:1 to 2.50:1, or from 1.50:1 to 2.50:1).Additional Alloy Compositions

[0048] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 6.Table 6PATENT Attorney Docket No. 108050-1523992

[0049] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 7.Table 7

[0050] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 8.Table 8PATENT Attorney Docket No. 108050-1523992

[0051] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 9.Table 9

[0052] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 10.Table 10PATENT Attorney Docket No. 108050-1523992

[0053] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 11.Table 11Silicon (Si)

[0054] In some examples, the alloy includes Si in an amount from 0.40 % to 1.30 % (e.g., from 0.50 % to 1.20 %, from 0.60 % to 1.10 %, from 0.70 % to 1.10 %, or from 0.50 % to 0.70 %) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 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 % Si. All percentages are expressed in wt. %.Iron (Fe)PATENT Attorney Docket No. 108050-1523992

[0055] In some examples, the alloy includes Fe in an amount from 0.50 % to 2.50 % (e.g., from 0.50 % to 2.25 %, from 0.50 % to 2.00 %, from 0.60 % to 1.80 %, from 0.70 % to 1.50 %, from 0.90 % to 1.40 %, or from 0.70 % to 1.20 %) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 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 %, 2.48 %, 2.49 %, or 2.50 % Fe. All percentages are expressed in wt. %.Copper (Cu)

[0056] In some examples, the alloy includes Cu in an amount from 0.10 % to 0.40 % (e.g., from 0.10 % to 0.30 %, from 0.15 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.40 % Cu. All percentages are expressed in wt. %. Manganese (Mn)

[0057] In some examples, the alloy includes Mn in an amount up to 1.00 % (e.g., up to 1.00 %, up to 0.90 %, up to 0.80 %, from 0.50 % to 1.00 %, from 0.50 % to 0.90 %, fromPATENT Attorney Docket No. 108050-15239920.60 % to 0.90 %, from 0.60 % to 0.80 %, or from 0.50 % to 1.00 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 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 %, or 1.00 % Mn. In some embodiments, the aluminum alloy composition includes 0 % Mn. All percentages are expressed in wt. %.Magnesium (Mg)

[0058] In some examples, the alloy includes Mg in an amount from 0.40 % to 0.80 % (e.g., from 0.50 % to 0.80 %, from 0.60 % to 0.80 %, or from 0.40 % to 0.60 %) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, or 0.80 % Mg. All percentages are expressed in wt. %.Zinc (Zn)

[0059] In some examples, the alloy includes Zn in an amount up to 3.50 % (e.g., up to 3.25 %, up to 3.00 %, up to 2.75 %, up to 2.50 %, up to 2.25 %, or up to 2.00 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 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 %,PATENT Attorney Docket No. 108050-15239920.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %, 1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %, 1.44 %, 1.45 %, 1.46 %, 1.47 %, 1.48 %, 1.49 %, 1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %, 1.55 %, 1.56 %, 1.57 %, 1.58 %, 1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %, 1.66 %, 1.67 %, 1.68 %, 1.69 %, 1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %, 1.77 %, 1.78 %, 1.79 %, 1.80 %, 1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %, 1.88 %, 1.89 %, 1.90 %, 1.91 %, 1.92 %, 1.93 %, 1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %, 1.99 %, 2.00 %, 2.01 %, 2.02 %, 2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %, 2.10 %, 2.11 %, 2.12 %, 2.13 %, 2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %, 2.21 %, 2.22 %, 2.23 %, 2.24 %, 2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %, 2.32 %, 2.33 %, 2.34 %, 2.35 %, 2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %, 2.43 %, 2.44 %, 2.45 %, 2.46 %, 2.47 %, 2.48 %, 2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %, 2.54 %, 2.55 %, 2.56 %, 2.57 %, 2.58 %, 2.59 %, 2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %, 2.65 %, 2.66 %, 2.67 %, 2.68 %, 2.69 %, 2.70 %, 2.71 %, 2.72 %, 2.73 %, 2.74 %, 2.75 %, 2.76 %, 2.77 %, 2.78 %, 2.79 %, 2.80 %, 2.81 %, 2.82 %, 2.83 %, 2.84 %, 2.85 %, 2.86 %, 2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %, 2.92 %, 2.93 %, 2.94 %, 2.95 %, 2.96 %, 2.97 %, 2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %, 3.03 %, 3.04 %, 3.05 %, 3.06 %, 3.07 %, 3.08 %, 3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %, 3.14 %, 3.15 %, 3.16 %, 3.17 %, 3.18 %, 3.19 %, 3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %, 3.25 %, 3.26 %, 3.27 %, 3.28 %, 3.29 %, 3.30 %, 3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %, 3.36 %, 3.37 %, 3.38 %, 3.39 %, 3.40 %, 3.41 %, 3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %, 3.47 %, 3.48 %, 3.49 %, or 3.50 % Zn. In some embodiments, the aluminum alloy composition includes 0 % Zn. All percentages are expressed in wt. %. The Zn content can optionally be provided to improve the corrosion potential of the aluminum alloys described herein. Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin. In some embodiments, the aluminum alloy includes at least 1.30 wt. %, such as at least 1.40 wt. %, at least 1.50 wt. %, or at least 1.60 wt. % Zn to provide good corrosion potential.Chromium (Cr)

[0060] In some examples, the alloy includes Cr in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy. For example,PATENT Attorney Docket No. 108050-1523992the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 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. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.Titanium (Ti)

[0061] In some examples, the alloy includes Ti in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 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 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.

[0062] Optionally, the alloy 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 each. These impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, Sr, or combinations thereof. Accordingly, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.

[0063] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, up to 3.5 wt. % Zn, up to 0.05 wt. % Cr, up to 0.5 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0064] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, 0.50 - 3.50 wt. % Zn, up to 0.05 wt. % Cr, up to 0.5 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0065] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, 0.50 - 2.00 wt. % Zn, up to 0.05 wt. % Cr, up to 0.5 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.PATENT Attorney Docket No. 108050-1523992

[0066] In some embodiments, the aluminum alloy composition comprises 0.40 - 1.30 wt. % Si, 0.50 - 2.00 wt. % Fe, 0.10 - 0.40 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0067] In some embodiments, the aluminum alloy composition comprises 0.50 - 1.20 wt. % Si, 0.60 - 1.80 wt. % Fe, 0.10 - 0.30 wt. % Cu, 0.50 - 0.90 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.25 wt. % Zn, up to 0.15 wt. % Cr, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0068] In some embodiments, the aluminum alloy composition comprises 0.60 - 1.10 wt. % Si, 0.70 - 1.50 wt. % Fe, 0.10 - 0.30 wt. % Cu, 0.60 - 0.90 wt. % Mn, 0.50 - 0.80 wt. % Mg, up to 3.00 wt. % Zn, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0069] In some embodiments, the aluminum alloy composition comprises 0.70 - 1.10 wt. % Si, 0.90 - 1.40 wt. % Fe, 0.15 - 0.25 wt. % Cu, 0.60 - 0.80 wt. % Mn, 0.50 - 0.70 wt. % Mg, up to 2.75 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0070] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, up to 2.50 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.

[0071] In the aforementioned embodiments, the aluminum alloy may include 0 wt. % Zn, based on the total weight of the aluminum alloy composition. For example, in embodiments where the aluminum alloy has sufficient corrosion potential or the aluminum alloy does not require a specific corrosion potential, little or no Zn is added to the aluminum alloy.

[0072] In some embodiments, the aluminum alloy comprises a combined content of Si and Fe of at least 1.00 % (e.g., at least 1.10 %, at least 1.20%, at least 1.25 %, at least 1.30 %, at least 1.40 %, or at least 1.50 %). In some embodiments, the aluminum alloy comprises a combined content of Si and Fe from 1.00 % to 4.20 % (e.g., from 1.25 % to 4.00 %, from 1.30 % to 3.75 %, from 1.40 % to 3.50 %, from 1.50 % to 3.50 %, from 2.00 % to 4.00 %, from 2.50 % to 3.50 %, or from 3.00 % to 4.00 %). All percentages are expressed in wt. %.

[0073] In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 1.50:1 (e.g., at least 1.60:1, at least 1.70:1, at least 1.80:1, at least 1.90:1, at least 2.0:1, at least 2.10:1, at least 2.20:1, at least 2.30:1, at least 2.40:1, or at least 2.50:1). In somePATENT Attorney Docket No. 108050-1523992embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn from 1.50: 1 to 4.50: 1 (e.g., from 1.75: 1 to 4.00: 1, from 1.80: 1 to 3.75: 1, from 1.90:1 to 3.50: 1, from 2.00: 1 to 3.00: 1, or from 1.50: 1 to 2.50: 1).High Fe Aluminum Alloy Compositions

[0074] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 12.Table 12

[0075] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 13.Table 13PATENT Attorney Docket No. 108050-1523992

[0076] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 14.Table 14

[0077] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 15.Table 15PATENT Attorney Docket No. 108050-1523992

[0078] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 16.Table 16Silicon (Si)

[0079] In some examples, the alloy includes Si in an amount from 0.10 % to 1.30 % (e.g., from 0.20 % to 1.20 %, from 0.30 % to 1.10 %, from 0.60 % to 0.90 %, from 0.50 % to 1.00 %, from 0.60 % to 1.00 %, or from 0.80 % to 1.30 %) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 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 %,PATENT Attorney Docket No. 108050-15239920.83 %, 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 % Si. All percentages are expressed in wt. %.Iron (Fe)

[0080] In some examples, the alloy includes Fe in an amount from 0.10 % to 2.50 % (e.g., from 0.50 % to 2.25 %, from 0.60 % to 2.00 %, from 0.75 % to 2.00 %, from 0.80 % to 2.00 %, from 0.90 % to 2.00%, or from 1.00 % to 2.00 %) based on the total weight of the alloy. For example, the alloy can include 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 %, 0.68 %, 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 %, 2.48 %, 2.49 %, or 2.50 % Fe. All percentages are expressed in wt. %.Copper (Cu)PATENT Attorney Docket No. 108050-1523992

[0081] In some examples, the alloy includes Cu in an amount from 0 % to 0.30 % (e.g., from 0.01 % to 0.30 %, from 0.01 % to 0.25 %, from 0.01 % to 0.20 %, or from 0.10 % to 0.30 %) based on the total weight of the alloy. For example, the alloy can include 0 %, 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 percentages are expressed in wt. %.Manganese (Mn)

[0082] In some examples, the alloy included Mn in an amount from 0.01 % to 0.80% (e.g., from 0.05 % to 0.70 %, from 0.10 % to 0.70 %, from 0.20 % to 0.80 %, from 0.30 % to 0.70 %, or from 0.30 % to 0.50 %) 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 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, or 0.80 % Mn. All percentages are expressed in wt. %. Magnesium (Mg)

[0083] In some examples, the alloy includes Mg in an amount from 0.20 % to 0.80% (e.g., from 0.20 % to 0.80 %, from 0.25 % to 0.80 %, or from 0.30 % to 0.80 %) 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 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, or 0.80 % Mg. All percentages are expressed in wt. %.Zinc (Zn)

[0084] In some examples, the alloy includes Zn in an amount from 0.50 % to 3.50% (e.g., from 0.50 % to 3.25 %, from 0.60 % to 3.00 %, from 0.60 % to 2.75 %, from 0.50 % to 2.50 %, from 0.60 % to 2.25 %, or from 0.70 % to 2.00%) based on the total weight of the alloy.PATENT Attorney Docket No. 108050-1523992For example, the alloy can include 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 %, 0.68 %, 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 %, 2.48 %, 2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %, 2.54 %, 2.55 %, 2.56 %, 2.57 %, 2.58 %, 2.59 %, 2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %, 2.65 %, 2.66 %, 2.67 %, 2.68 %, 2.69 %, 2.70 %, 2.71 %, 2.72 %, 2.73 %, 2.74 %, 2.75 %, 2.76 %, 2.77 %, 2.78 %, 2.79 %, 2.80 %, 2.81 %, 2.82 %, 2.83 %, 2.84 %, 2.85 %, 2.86 %, 2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %, 2.92 %, 2.93 %, 2.94 %, 2.95 %, 2.96 %, 2.97 %, 2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %, 3.03 %, 3.04 %, 3.05 %, 3.06 %, 3.07 %, 3.08 %, 3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %, 3.14 %, 3.15 %, 3.16 %, 3.17 %, 3.18 %, 3.19 %, 3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %, 3.25 %, 3.26 %, 3.27 %, 3.28 %, 3.29 %, 3.30 %, 3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %, 3.36 %, 3.37 %, 3.38 %, 3.39 %, 3.40 %, 3.41 %, 3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %, 3.47 %, 3.48 %, 3.49 %, or 3.50 % Zn. All percentages are expressed in wt. %. As discussed above, in some embodiments, the aluminum alloy includes at least 1.30 wt. %, such as at least 1.40 wt. %, at least 1.50 wt. %, or at least 1.60 wt. % Zn to provide good corrosion potentialPATENT Attorney Docket No. 108050-1523992Chromium (Cr)

[0085] In some examples, the alloy includes chromium (Cr) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 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. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.Titanium (Ti)

[0086] In some examples, the alloy includes titanium (Ti) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 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 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.

[0087] Optionally, the alloy compositions 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 each. These impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, Sr, or combinations thereof. Accordingly, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.

[0088] In some examples, suitable alloys for use in the alloys described herein can be a Ixxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, an 8xxx series aluminum alloy, or any combination thereof. The Ixxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, or 8xxx series aluminum alloy can be modified to include an amount of Mg, Cu, and / or Si as described above.

[0089] However, in embodiments, the alloy may be a 3xxx series alloy. Suitable 3xxx series aluminum alloys for use in the alloys described herein include, for example, AA3002,PATENT Attorney Docket No. 108050-1523992AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.Recycled Content

[0090] The aluminum alloys described herein can tolerate higher amounts of recycled aluminum alloy materials 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 tailored aluminum alloy composition to compensate for the impurities. This enables a higher amount of less expensive, higher impurity recycled aluminum alloy materials (e.g., used 3xxx series aluminum alloy) for producing aluminum alloys that can still exhibit desirable properties. The aluminum alloy compositions described herein can include higher amounts of recycled aluminum alloy materials compared to AA7072 aluminum alloy with little or no additional primary aluminum.

[0091] In some embodiments, the aluminum alloy composition described herein provides a composition that is well-suited for utilizing used AA3105 aluminum alloy scrap as recycle material. In some embodiments, the aluminum alloy composition described herein can utilize UBC scrap. UBC scrap is a mixture of various aluminum alloys (e.g., from different aluminum alloys used for can bodies and can ends). UBC scrap generally includes a mixture of metal from various aluminum alloys, such as metal from can bodies (e.g., AA3104, AA3004, or other 3xxx series aluminum alloys) and can ends (e.g., AA5182 or other 5xxx series aluminum alloys). UBC scrap can be shredded and de-coated or de-lacquered prior to being melted for use as liquid metal stock in casting a new metal product.

[0092] As discussed herein, the aluminum alloy composition described herein can utilize recycled aluminum alloy materials (e.g., used AA3105 aluminum alloy scrap) to produce the aluminum alloy due to the aluminum alloy composition. This allows the use of more recycled aluminum alloy materials for producing fin end stock and reduces the amount of primary aluminum. In some aspects, the aluminum alloys described herein include a high amount of recycled aluminum alloy materials scrap at or greater than 25 %, e.g., at or greater than 30 %, at or greater than 35 %, at or greater than 40 %, at or greater than 45 %, at or greater than 50 %, at or greater than 55 %, at or greater than 60 %, at or greater than 65 %, at or greater than 70 %, or at or greater than 75 %. In terms of ranges, the aluminum alloys described hereinPATENT Attorney Docket No. 108050-1523992can include from 25 % to 90 % recycled aluminum alloy materials (e.g., from 25 % to 85 %, from 30 % to 80 %, from 35 % to 75 %, from 40 % to 70 %, from 50 % to 70 %, or from 35 % to 50 %). As discussed above, in some aspects the aluminum alloys described herein are particularly well-suited to utilize used AA3105 aluminum alloy scrap.

[0093] In some aspects, the aluminum alloys described herein include less than 30 % primary aluminum, e.g., less than 30 %, less than 29 %, less than 28 %, less than 27 %, less than 26 %, less than 25 %, less than 24 %, less than 23 %, less than 22 %, less than 21 %, or less than 20 %. All are expressed in wt. %.

[0094] In embodiments, regardless of the series formed, the aluminum alloys described herein can contain at least 40 wt. % recycled content. For example, the aluminum alloys can contain at least 45 wt. %, at least 50 wt. %, at least 55 wt. %, at least 60 wt. %, at least 70 wt. %, at least 75 wt.%, at least 80 wt. %, at least 85 wt.%, at least 90 wt. %, at least 95 wt. %, at least 99 wt. % recycled content, or even up to 100 wt.% recycled content, based upon the weight of the aluminum alloy.Cast Aluminum Alloy

[0095] FIG. 1 is a partial cut-away view of an exemplary DC casting system 100 which may be utilized in aspects of the present disclosure. A metal source 102, such as a tundish, can supply molten metal down a feed tube 104 and out a nozzle 106. An optional skimmer 108 can be used around the feed tube 104 to help distribute the molten metal and reduce generation of metal oxides at the upper surface of the molten sump 110. A bottom block 120 may be lifted by a hydraulic cylinder 122 to meet the walls of the mold cavity 112. As molten metal begins to solidify within the mold, the bottom block 120 can be steadily lowered at a casting speed. The embryonic ingot 116 can include sides 118 that have solidified, while molten metal added to the cast can be used to continuously lengthen the embryonic ingot 116. The embryonic ingot 116 can include a bottom end 136. In some cases, the walls of the mold cavity 112 define a hollow space and may contain a coolant 114, such as water. The coolant 114 can exit as jets from the hollow space and flow down the sides 118 of the embryonic ingot 116 to help solidify the embryonic ingot 116. The embryonic ingot 116 can include an external solid shell 128, a transitional metal region (e.g., solidifying interface 126), and a molten metal core 124.

[0096] In embodiments, the solidified shell 128 of the embryonic ingot 116 is reheated commencing at a reheater distance 130, defined as the distance from the bottom of the mold cavity 112 (e.g., where the embryonic ingot 116 exits the mold cavity 112) to the locationPATENT Attorney Docket No. 108050-1523992where the solid shell 118 begins reheating. The reheater distance 130 can be the distance between the mold and a location where reheating begins (e.g., location of a reheating device, such as a wiper 142 used to remove coolant 114). The location of where reheating begins can be known as a transition location.

[0097] While various techniques can be used to reheat the solid shell 128, FIG. 1 depicts the use of a wiper 142 to remove coolant 114 from the embryonic ingot 116. The wiper 142 of FIG. 1 is depicted as a solid wiper, however other wipers can be used as well, such as fluid-based wipers (e.g., air knives). The coolant 114 is removed from the embryonic ingot 116 at a cross section where the core of the embryonic ingot 116 is still molten. Thus, latent heat from the molten metal core 124, especially from regions of the molten metal core 124 between the reheater distance 130 and the molten metal distance 132 (defined below), can reheat the solid shell 128. Thus, as described in further detail herein, by adjusting the reheater distance 130 and / or the molten metal distance 132, the timing and amount of reheating can be precisely controlled.

[0098] The reheater distance 130 can be shorter than a molten metal distance 132 and a sump distance 134. The molten metal distance 132 can be defined as the distance from the bottom of the mold cavity 112 to the bottom of the molten metal core 124. The sump distance 134 can be defined as the distance from the bottom of the mold cavity 112 to the bottom of the solidifying interface 126.

[0099] In embodiments, the difference between the molten metal distance 132 and the reheater distance 130 can be controlled, such as by inducing changes in the shape of the molten metal core 132 (e.g., by changing casting speed and / or inducing stirring) to adjust the molten metal distance 132, or by moving the wiper 142 to adjust the reheater distance 130. Such casting speed, stirring and / or wiper 142 adjustments can be controlled by a controller 138 coupled to any appropriate actuators. In some cases, controller 138 can perform operations based on a preset routine. In some cases, controller 138 can perform operations based on dynamic feedback from the casting process, such as from temperature measurements taken by a sensor 144. Sensor 144 can be any suitable temperature sensor, such as a contacting or non-contact sensor. Sensor 144 of FIG. 1 is depicted adjacent the solid shell 128 to take a measurement of the surface of the solid shell 128, however that need not be the case. In some cases, sensor(s) can be placed in other locations and can take other ingot measurements, such as sump temperature or coolant temperature.PATENT Attorney Docket No. 108050-1523992

[0100] An optional flow controller 140 can be positioned to control flow of molten metal through the feed tube 104. Examples of suitable flow controllers 140 include retractable pins for slowing and / or halting metal flow, magnetic pumps, electric pumps, or any suitable device for increasing and / or decreasing the flow of metal through the feed tube 104.

[0101] While a wiper system is depicted in FIG. 1, other types of reheating techniques can be used at the reheater distance 130 instead of or in addition to a wiper system. For example, direct flame impingement, rotating magnetic heaters, or other devices can be used to apply heat to the solid shell 128 in addition to any latent heat from the molten metal core 124. In some cases, these techniques for applying heat to the solid shell 128 can be controlled, such as controlling an amount of heat provided and / or location where the heat is provided. Such control can be performed by a controller 138.

[0102] Referring next to FIG. 2, an exemplary process for forming an aluminum alloy product is provided. In embodiments, an aluminum alloy, which may be any one or more after the aluminum alloy is formed by one or more methods as known in the art, at operation 201. After formation of the alloy, the alloy may be cast, such as by direct chill casting, at operation 202. In embodiments, DC casting may occur utilizing the apparatus discussed above, or otherwise as known in the art. Nonetheless, the cast aluminum alloy may be withdrawn from the cast, such as in the form an aluminum ingot, which may then be subjected to further processing steps. In some non-limiting examples, the processing method includes homogenizing 204, soaking, 206, hot rolling 208, and cold rolling the ingot 210 to form an aluminum product, which will be discussed in greater detail below. In some cases, the aluminum ingot is further processed through an annealing step 211. In other cases, the further processing steps include a ramped annealing step 211. In still some other cases, the further processing steps include a tempering step 212.Homogenization

[0103] For instance, following the casting step, one or more homogenization operations 204 are performed after the casting operation 203, such as immediately subsequent in embodiments. In embodiments, an initial homogenization operation can include subjecting the cast aluminum ingot to a temperature ranging from 500 °C to 650 °C. For example, the homogenization step can be performed at a temperature of 500 °C, 510 °C, 520 °C, 530 °C, 540 °C, 550 °C, 560 °C, 570 °C, 580 °C, 590 °C, 600 °C, 610 °C, 620 °C, 630 °C, 640 °C, 650 °C, or any ranges or values therebetween. The ingot can be subjected to any of these initial homogenization temperatures for a range of time from 1 hour to 5 hours. For example,PATENT Attorney Docket No. 108050-1523992the ingot may be subjected to the homogenization temperature for 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, or anywhere in between.

[0104] In embodiments, the initial homogenization temperature may be achieved by subjecting the cast aluminum alloy to a temperature that increases at set time periods, until the target temperature is achieved, at which point the temperature is maintained for one or more of the above time periods. Such as process may be referred to as “ramping”. In embodiments, the temperature may be increased by 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, or more, every 10 minutes, 20 minutes, 30 minutes, 40 minutes, 50 minutes, 1 hour, or more, until the target temperature is achieved. However, it should be clear that other ramping times and temperatures are contemplated herein as known in the art.

[0105] For 3xxx series aluminum alloys, homogenization is an important step in the heat treatment process of cast aluminum in that it aims to eliminate chemical segregation and create a uniform microstructure. This process also has a significant impact on the precipitation of dispersoids. An additional phase that includes Mg2Si is formed at temperatures in the lower range of homogenization temperatures and closer to lay on temperatures. During the casting process, elements such as manganese (Mn) may segregate, leading to regions of varying composition within the alloy. The homogenization allows alloying elements to diffuse throughout the matrix of a metal, which reduces chemical gradients and homogenizes the composition throughout the material. The homogenization process can further influence the number and distribution of nucleation sites for dispersoid formation. By carefully controlling the homogenization temperature and time, the growth of dispersoids can be controlled to achieve precipitation of solute elements, which inhibit thermal and electrical conductivity, out of solution and into the dispersoids in the alpha phase and other second phase particles, allowing for improvements in the thermal and electrical conductivity of the aluminum alloy. However, it should be clear that, in embodiments, the homogenization temperature and time may be utilized after hot rolling, during cold rolling, after cold rolling, or a combination thereof, as the time and temperature discussed herein allows precipitation of the solutes in sufficient amounts to produce the improvements in thermal and electrical conductivity discussed herein. Thus, in embodiments, depending upon when the homogenization is performed, the heating and soaking of the material may be considered to be a stand alone heat treatment.

[0106] Following the initial homogenization of the ingot 205, a homogenization soaking operation 206 is performed. The soaking operation 206 includes reducing the temperaturePATENT Attorney Docket No. 108050-1523992from the homogenization temperature to a soaking temperature ranging from 350 °C to 600 °C, such as 380 °C to 550 °C, or such as 400 °C to 500 °C. For example, the soaking step can be performed at a temperature of 350 °C, 360 °C, 370 °C, 380 °C, 390 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, 460 °C, 470 °C, 480 °C, 490 °C, 500 °C, 510 °C, 520 °C, 530 °C, 540 °C, 550 °C, or anywhere in between. Nonetheless in embodiments, it may be desired to utilize a relatively “low temperature” homogenization soaking temperature, such as less than 550 °C, less than 540 °C, less than 530 °C, less than 520 °C, less than 510 °C, less than 500 °C, or less. Namely, while higher homogenization temperatures are useful for suspending the alloying elements, including Mn in the alloy, maintained high temperatures may re-dissolve the solute elements, and therefore inhibit alpha and beta phase growth. Thus, in embodiments, a soaking homogenization temperature may be selected so as to target nucleation, growth, and coarsening of the alpha phase dispersoids. Furthermore, the present technology has also found that such a homogenization soaking process may also facilitate the transformation of beta phase particles into alpha phase particles, further reducing the amount of Mn present in the aluminum matrix. The homogenized ingot can subject subjected to the homogenization soaking for range of time from 1 hour to 15 hours (e.g., 2 to 14 hours, 5 hours to 12 hours, etc.). For example, the ingot may be subjected to the soaking temperature for 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, or anywhere in between. In embodiments, the ingot may be soaked in a nitrogen atmosphere.

[0107] In embodiments, the homogenization soaking temperature may be achieved by subjecting the cast aluminum alloy to a temperature that decreases at set time periods, until the target temperature is achieved, at which point the temperature is maintained for one or more of the above time periods. Such as process may be referred to as “ramping”. In embodiments, the temperature may be decreased by 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, or more, every 10 minutes, 20 minutes, 30 minutes, 40 minutes, 50 minutes, 1 hour, or more, until the target temperature is achieved. However, it should be clear that other ramping times and temperatures are contemplated herein as known in the art.

[0108] As discussed above, homogenization soaking step 206 described herein may be particularly important for the formation of the alpha phase Ali2(Fe,Mn)3Si dispersoids. Not to be bound by theory, at the higher homogenization temperature, Mg2Si is dissolved into the aluminum matrix, driving up the Mg and Si content. This increase in Si in the matrix, andPATENT Attorney Docket No. 108050-1523992potentially Fe, is believed to help drive the nucleation and precipitation of the alpha phase within the aluminum matrix. The soaking step also allows the alloying elements (such as Mn in the case of 3xxx series aluminum) to become more uniformly distributed within the aluminum matrix and further drive the precipitation of the alpha phase, without re-dissolving the nucleated particles, thus reducing the amount of Mn in the aluminum matrix. As previously mentioned, this decrease in Mn content within the matrix has been shown to increase the electrical and thermal conductivity of 3xxx series aluminum alloys.Hot Rolling

[0109] Following the soaking step 207, a hot rolling step 208 can be performed to produce a hot rolled aluminum alloy. In some cases, the hot rolling step can be performed immediately after the soaking 207. The hot rolling step can include a hot reversing mill operation and / or a hot tandem mill operation. The hot rolling step can be performed at a temperature ranging from 200 °C to 500 °C (e.g., from 225 °C to 400 °C or from 250 °C to 350 °C). For example, the hot rolling step can be performed at a temperature of 250 °C, 260 °C, 270 °C, 280 °C, 290 °C, 300 °C, 310 °C, 320 °C, 330 °C, 340 °C, 350 °C, 360 °C, 370 °C, 380 °C, 390 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, 460 °C, 470 °C, 480 °C, 490 °C, 500 °C, or anywhere in between.

[0110] In the hot rolling step, the homogenized ingot can be hot rolled to a thickness of 15 mm or less (e.g., from 0.5 mm to 10 mm), providing an aluminum alloy hot band. For example, the cast aluminum alloy product can be hot rolled to a 15 mm gauge or less, a 14 mm gauge or less, a 13 mm gauge or less, a 12 mm gauge or less, an 11 mm gauge or less, a 10 mm gauge or less, a 9 mm gauge or less, an 8 mm gauge or less, a 7 mm gauge or less, a 6 mm gauge or less, a 5 mm gauge or less, a 4 mm gauge or less, a 3 mm gauge or less, a 2 mm gauge or less, or a 1 mm gauge or less. In some cases, the percentage reduction in thickness resulting from the hot rolling step can be at least 40 % (e.g., from 40 % to 95 %). For example, the thickness of the cast aluminum alloy product can be reduced by 40 %, 45 %, 50 %, 55 %, 60 %, 65 %, 70 %, 75 %, 80 %, 85 %, 90 %, or 95%.Annealing

[0111] Optionally, the rolled aluminum product can be further process through one or more annealing operations. The annealing may occur before and / or after a cold rolling operation, after a hot rolling operation, or a combination thereof. Thus, while only optional operation 211 is illustrated, it should be understood that the anneal may be utilized to simulate a self annealing, such as prior to operation 211, or may be a temper annealing thatPATENT Attorney Docket No. 108050-1523992occurs after operation 211. The annealing step can be performed by subjecting the aluminum alloy product to an annealing temperature ranging from 300 °C to 450 °C. For example, the annealing temperature can be 300 °C, 310 °C, 320 °C, 330 °C, 340 °C, 350 °C, 360 °C, 370 °C, 380 °C, 390 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, or anywhere in between. The annealing can be performed for a period of time from 3 hours to 10 hours. For example, the aluminum alloy product can be subjected to the annealing temperature for 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, or anywhere in between.

[0112] Optionally, in some embodiments, the annealing 211 can be a ramped annealing at a heating rate of at least 10° C / h. For example, the heating rate can be 10° C / h, 15° C / h, 20° C / h, 25° C / h, 30° C / h, 35° C / h, 40° C / h, 45° C / h, 50° C / h, 55° C / h, 60° C / h, 65° C / h, 70° C / h, 75° C / h, or greater than 80° C / h. The ramped annealing can be performed for a period of time from 1 hours to 5 hours. For example, the ramped annealing can be performed for 1 hour, 2 hours, 3 hours, 4 hours, 5 hours.

[0113] Annealing can be used to reduce the hardness of an aluminum alloy product, making the aluminum more ductile and easier to work with. This may be useful for subsequent processes such as machining, stamping, and forming. Further, annealing aluminum can further improve electrical and thermal conductivity by reducing defects and impurities within its crystal structure. In addition, as discussed above, annealing discussed herein may also serve to remove free solute elements from solution, improving the electrical properties of the product. Ramped annealing can allow for reduce the risk of thermal gradients that may occur as a result of faster heating by gradually heating and / or cooling of the aluminum.Cold rolling

[0114] Following hot rolling 209, a cold rolling step 210 can be performed to produce an aluminum alloy product. The cold rolling may reduce the thickness of the aluminum alloy product by greater than or about 75% of a thickness of the aluminum alloy product after one of more hot rolling operations. For example, the cold rolling may reduce the thickness of the aluminum alloy product by about 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or greater than 99%.

[0115] Cold rolling is used to achieve precise thickness reductions, producing an aluminum product which may include thin sheets, plates, strips, or foils. Cold rolling induces strain hardening (also known as work hardening) in the aluminum alloy, which increases itsPATENT Attorney Docket No. 108050-1523992strength and hardness. This makes the aluminum product more durable and suitable for certain applications while minimally affecting the thermal and electrical conductivity.Tempering

[0116] Optionally, in further embodiments, the annealed aluminum alloy product can be tempered through solutionizing, quenching, and aging the annealed aluminum alloy product 212. The methods described herein further include a step of solutionizing the annealed aluminum alloy product. The solutionizing step can include heating or cooling, as necessary, the annealed aluminum product to a solutionizing temperature of 450 °C or greater (e.g., from 460 °C to 600 °C, from 465 °C to 575 °C, from 470 °C to 550 °C, from 475 °C to 525 °C, or from 480 °C to 500 °C). The annealed aluminum alloy product can soak at the solutionizing temperature for a period of time. In certain aspects, the annealed aluminum alloy product is allowed to soak for at least 30 seconds (e.g., from 60 seconds to 120 minutes, inclusively). For example, the annealed aluminum product can be soaked at the temperature of 450 °C or greater for 30 seconds, 35 seconds, 40 seconds, 45 seconds, 50 seconds, 55 seconds, 60 seconds, 65 seconds, 70 seconds, 75 seconds, 80 seconds, 85 seconds, 90 seconds, 95 seconds, 100 seconds, 105 seconds, 110 seconds, 115 seconds, 120 seconds, 125 seconds, 130 seconds, 135 seconds, 140 seconds, 145 seconds, 150 seconds, 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes, 40 minutes, 45 minutes, 50 minutes, 55 minutes, 60 minutes, 65 minutes, 70 minutes, 75 minutes, 80 minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, 105 minutes, 110 minutes, 115 minutes, or 120 minutes, or anywhere in between.Quenching

[0117] The methods 200 described herein can include a quenching step, and / or an additional quenching step than discussed above. The term “quenching,” as used herein, can include rapidly reducing a temperature of an aluminum alloy product that has been solutionized as described above. In the quenching step, the product can be quenched with a liquid (e.g., water), gas (air), any other suitable quench medium, or any combination thereof. In certain aspects, the product can be quenched using water having a water temperature of between 40 °C and 75 °C. In certain aspects, the product is quenched using forced air.

[0118] In certain aspects, the product can be cooled to a temperature of 25 °C to 65 °C at a quench speed that can vary between 10 °C / s to 400 °C / s in a quenching step. For example, the quench rate can be from 10 °C / s to 375 °C / s, from 15 °C / s to 350 °C / s, from 20 °C / s toPATENT Attorney Docket No. 108050-1523992300 °C / s, from 25 °C / s to 275 °C / s, from 30 °C / s to 250 °C / s, from 40 °C / s to 225 °C / s, from 50 °C / s to 200 °C / s, from 60 °C / s to 175 °C / s, or from 70 °C / s to 150 °C / s.Pre-Aging

[0119] In some cases, a pre-aging step can be performed. Optionally, the pre-aging step can be performed before the solutionizing step or after the solutionizing step. The pre-aging step can include heating the aluminum alloy product to a pre-aging temperature of from 50 °C to 300 °C (e.g., from 75 °C to 250 °C, from 100 °C to 300 °C, from 100 °C to 275 °C, or from 100 °C to 250 °C). For example, the pre-aging step can include heating the aluminum product to a temperature of 50 °C, 55 °C, 60 °C, 65 °C, 70 °C, 75 °C, 80 °C, 85 °C, 90 °C, 95 °C, 100 °C, 105 °C, 110 °C, 115 °C, 120 °C, 125 °C, 130 °C, 135 °C, 140 °C, 145 °C, 150 °C, 155 °C, 160 °C, 165 °C, 170 °C, 175 °C, 180 °C, 185 °C, 190 °C, 195 °C, 200 °C, 205 °C, 210 °C, 215 °C, 220 °C, 225 °C, 230 °C, 235 °C, 240 °C, 245 °C, 250 °C, 255 °C, 260 °C, 265 °C, 270 °C, 275 °C, 280 °C, 285 °C, 290 °C, 295 °C, 300 °C. The aluminum alloy product can be maintained at the pre-aging temperature for a period of up to 72 hours (e.g., from 1 hour to 72 hours). For example, the aluminum alloy product can be maintained for 72 hours or less, 60 hours or less, 48 hours or less, 36 hours or less, 24 hours or less, 12 hours or less, 6 hours or less, 5 hours or less, 4 hours or less, 3 hours or less, 2 hours or less, 1 hour or less, or anywhere in between.Aging

[0120] After the solutionizing, quenching and / or pre-aging steps, one or more aging steps can be performed. The aging can include one or more of natural aging, artificial aging, paint baking, and post-forming heat treating.

[0121] Optionally, the aging can include a natural aging step. The natural aging can include a step of maintaining the aluminum alloy product at room temperature for a period of time. For example, the aluminum alloy product can be maintained at room temperature for up to 12 weeks (e.g., 1 day, 2 days, 3 days, 4 days, 5 days, 6 days, 1 week, 2 weeks, 3 weeks, 4 weeks, 5 weeks, 6 weeks, 7 weeks, 8 weeks, 9 weeks, 10 weeks, 11 weeks, or 12 weeks).

[0122] Aluminum alloy products prepared according to the methods described herein can be delivered after being subjected to the optional pre-aging and natural aging. The aluminum alloy products can achieve high yield strengths after processing by an end user, for example, by deforming (e.g., stamping, pressing, forming, or any suitable deforming process) and / or by aging or thermal treatment (e.g., coating and paint baking, artificial aging, post-forming heat treatment, or any suitable end user thermal treatment). Optionally, after the optional pre-PATENT Attorney Docket No. 108050-1523992aging and / or natural aging step, the aluminum alloy products described herein are subjected to, for example, a forming process, a coating process, an artificial aging step, and / or a paint baking process.

[0123] Optionally, the aging can include an artificial aging step. The artificial aging can include heating the aluminum alloy product to an artificial aging temperature of from 80 °C to 250 °C (e.g., from 80 °C to 225 °C, from 100 °C to 225 °C, from 100 °C to 225 °C, from 110 °C to 220 °C, from 115 °C to 210 °C, or from 120 °C to 210 °C, from 125 °C to 225 °C, from 140 °C to 225 °C, from 160 °C to 225 °C, from 180 °C to 225 °C, from 200 °C to 225°C, and all combinations of endpoints). The artificial aging step can include maintaining the artificial aging temperature for a period of from 30 minutes hours to 72 hours (e.g., 1 hour, 2 hours, 4 hours, 8 hours, 10 hours, 12 hours, 15 hours, 20 hours, 24 hours, 30 hours 48 hours, 60 hours, or 72 hours, including combinations of all endpoints).

[0124] In some aspects, an optional coating procedure can be performed (e.g., painting, electrocoating, or zinc-phosphating, to name a few). After coating, the aluminum alloy product can be subjected to further thermal treatment including paint baking, post-forming heat treatment, any suitable OEM thermal treatment process, or any combination thereof. The paint bake can further strengthen the aluminum alloy product providing a high strength aluminum alloy product having an optionally complex formed shape. In some cases, a paint baking procedure can include heating the aluminum alloy product to a paint baking temperature of from 75 °C to 250 °C and maintaining the aluminum alloy product at the paint baking temperature for a period of up to 3 hours (e.g., from 15 minutes to 2 hours, from 15 minutes to 45 minutes, or from 30 minutes to 1 hour). In some aspects, the at least one paint baking step may be is conducted at a temperature from 75 to 250 °C for a period of from 15 minutes to 3 hours, at a temperature from 100 to 200 °C for a period of from 15 minutes to 2 hours, or at a temperature from 150 to 180 °C for a period of from 15 minutes to 45 minutes.

[0125] In some further cases, a post-forming heat treatment can be performed. The postforming heat treatment procedure can include heating the aluminum alloy product to a postforming heat treating temperature of from 100 °C to 250 °C and maintaining this temperature for 1 hour to 24 hours (e.g., from 2 hours to 12 hours), or any anneal temperatures and time as known in the art. In some embodiments, the method of forming the aluminum alloy described herein may comprise at least one paint bake treatment. In some embodiments, the method of making the aluminum alloy described herein may comprise at least 2 paint bake treatments. The method of making the aluminum alloy described herein may comprise from 1PATENT Attorney Docket No. 108050-1523992to 5 paint bake treatments. For example, the method of making the aluminum alloy described herein may include 1 paint bake treatment, 2 paint bake treatments, 3 paint bake treatments, 4 paint bake treatments, 5 paint bake treatments, or greater than 5 paint bake treatments.Alloy Product Properties

[0126] The aluminum alloy products described herein can have formability and high thermal and electrical properties compared to other 3xxx series aluminum. In some aspects, the aluminum alloy product is formable at a temperature below room temperature, e.g., from 0 to up to 15 °C. In some aspects, the aluminum alloy product is formable at ambient (room) temperature and may be formable at temperatures up to 40 °C.

[0127] In embodiments, the aluminum alloy product may exhibit electrical conductivity from 40 % to 60 % of copper, based on the international annealed copper standard (IACS), such as 40 %, 42 %, 44 %, 46 %, 48 %, 50 %, 52 %, 54 %, 56 %, 58 %, 60%, or any ranges or values therebetween. Stated differently, in embodiments, aluminum alloy products according to the present technology may exhibit a thermal conductivity that is at least about 70% of a 7xxx series alloy, such as a 7072 alloy, such as 72%, 74%, 76%, 78%, 80%, 82%, 84%, 86%, 88%, 90%, 92%, 94%, 96%, 98%, or 100%, or any ranges or values therebetween.

[0128] In embodiments, the aluminum alloy products exhibit a percent elongation after processing of about 1% to about 15% according to ASTM E8 / E8M-22 standard testing methods. For example, the aluminum alloy product can have a percent elongation of 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, or any ranges or values therebetween.

[0129] In aspects, the aluminum alloy products exhibit a yield strength greater than or about 60 MPa, such as 60 MPa to 250 MPa, 80 MPa to 240 MPA, or 100 MPa to 220 MPa. For example, the aluminum alloy products can exhibit a yield strength of 60 MPa or greater, 65 MPa greater, 70 MPa or greater, 75 MPa or greater, 80 MPa or greater, 90 MPa or greater, 100 MPa or greater, 110 MPa or greater, 120 MPa or greater, 130 MPa or greater, 140 MPa or greater, 150 MPa or greater, 160 MPa or grater 170 MPa or greater, 180 MPa or greater 190 MPa or greater, 200 MPa or greater, 210 MPa or greater, 220 MPa or greater, 230 MPa or greater, 240 MPa or greater, or any ranges or values therebetween, after processing according to the methods described herein.

[0130] In some examples, the aluminum alloy products have an ultimate tensile strength of greater than 130 MPa, such as 130 MPa to 300 MPa, 150 MPa to 290 MPa, 200 MPa toPATENT Attorney Docket No. 108050-1523992280 MPa, after processing according to the methods described herein. For example, the aluminum alloy products can have an ultimate tensile strength of 130 MPa or greater, 135 MPa or greater, 140 MPa or greater, 145 MPa or greater, 150 MPa or greater, 155 MPa or greater, 160 MPa or greater, 165 MPa or greater, 170 MPa or greater, or 175 MPa or greater, 180 MPa or greater, 190 MPa or greater, 200 MPa or greater 210 MPa or greater, 220 MPa or greater, 230 MPa or greater, 240 MPa or greater 250 MPa or greater, 260 MPa or greater, 270 MPa or greater, 280 MPa or greater, 290 MPa or greater, or any ranges or values therebetween, after processing according to the methods described herein.

[0131] In embodiments, after homogenization or annealing as discussed herein, the aluminum alloy matrix may contain less than 0.10 wt.% of the one or more solute elements, as some or all of the solute elements, such as Mn, Cr, or Mg, as examples only, may be trapped in the alpha phase or other second phases. Thus, in embodiments, the aluminum alloy matrix contains less than 0.095 wt.% of one or more solute elements, less than 0.090 wt.%, less than 0.085 wt.%, less than 0.080 wt.%, less than 0.075 wt.%, less than 0.070 wt.%, less than 0.065 wt.%, less than 0.060 wt.%, less than 0.055 wt.%, less than 0.50 wt.%, less than 0.045 wt.%, less than 0.040 wt.%, less than 0.035 wt.%, or any ranges or values therebetween. The above weight percentages may refer to a total amount of solute elements, or an amount of each respective solute element in the aluminum alloy matrix.

[0132] Furthermore, after homogenization or annealing as discussed herein, the aluminum alloy matrix may contain less than 0.10 wt.% Mn, as some or all of the Mn is trapped in the alpha phase. Thus, in embodiments, the aluminum alloy matrix contains less than 0.095 wt.% Mn, less than 0.090 wt.%, less than 0.085 wt.%, less than 0.080 wt.%, less than 0.075 wt.%, less than 0.070 wt.%, less than 0.065 wt.%, less than 0.060 wt.%, less than 0.055 wt.%, less than 0.50 wt.%, less than 0.045 wt.%, less than 0.040 wt.%, less than 0.035 wt.%, or any ranges or values therebetween.

[0133] In some aspects, the aluminum alloy products have an Olsen Cup Height, as measured according to ASTM E643: Standard Test Method for Ball Punch Deformation of Metallic Sheet Material, of greater than or about 0.10”, after processing according to the methods described herein. For example, the aluminum alloy products can have an Olsen Cup Height of 0.11” or greater, 0.12” or greater, 0.13” or greater, 0.14” or greater, 0.15” or greater, or any ranges or values therebetween, after processing according to the methods described herein.Methods of UsingPATENT Attorney Docket No. 108050-1523992

[0134] The alloy products and methods described herein can be used, but are not limited to, components of fin stocks, heat sinks, power transmission lines, automotive radiators, condensers and evaporators, LED lighting housings, busbars, transformer windings, cookware, heat exchangers, solar panel frames, electric motor windings, battery housings, electrical enclosures, electronic casings, telecommunications equipment, railway electrification systems, aircraft components, satellite and spacecraft components, marine electrical systems, medical devices, robotics components, industrial machinery, electric vehicle charging stations, welding electrodes, plating and coating equipment, printed circuit boards, power electronics, sensors, wind turbines, and consumer appliances due to their lightweight, conductive, and efficient heat transfer properties.

[0135] In embodiments, the products and methods can be utilized to prepare one or more fin stocks, such as a fin stock for a heat exchanger. However, the products and methods can be used in any other desired application.

[0136] 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.Example - DC Cast Alloys for Preparation of Fin Stock

[0137] 3xxx alloys were formed according to the following Table 1, with the balance being aluminum and impurities discussed herein:Table 1

[0138] Sample 1 was prepared by a two-step homogenization by an initial homogenization at 570-610 °C, followed by soaking at 460-500 °C. After thePATENT Attorney Docket No. 108050-1523992homogenization, sample 1 was hot rolled to a gauge of about 2.3 mm, and prepared for testing

[0139] Sample 2 was prepared by a two-step homogenization by an initial homogenization at 570-610 °C, followed by soaking at 460-500 °C. After the homogenization, sample 2 was hot rolled to a gauge of about 2.3 mm, and prepared for testing

[0140] Sample 3 was prepared by a two-step homogenization by an initial homogenization at 570-610 °C, followed by soaking at 460-500 °C. After the homogenization, sample 3 was hot rolled to a gauge of about 2.3 mm, and prepared for testing.

[0141] Sample 4 was prepared by a one step homogenization at 570-610 °C followed by hot rolling to a 2.3 mm gauge. Sample 4 was then subjected to an additional anneal at 380-440 °C for four hours.

[0142] Sample 5 was prepared in a similar manner to sample 3, by homogenization at 570-610 °C followed by soaking at 520-560 °C and hot rolling to a gauge of 2.3 mm, except that Sample 5 also underwent a anneal at a temperature of 380-440 °C for four hours.

[0143] Sample 6 was prepared in a similar manner by homogenization at 570-610 °C followed by soaking at 520-560 °C and hot rolling to a gauge of 2.3 mm. However, Sample 6 did not undergo a further annealing operation.

[0144] The above 3xxx alloys were tested against a commercial 7072 alloy for mechanical and conductivity suitability.

[0145] As shown in FIG. 1, each of the prepared 3xxx alloys met the minimum electrical conductivity of 90% of the 7072 control conductivity according to the IACS standard as measured according to ASTMB193 (2025).

[0146] Further, as shown in FIG. 2, each of the prepared 3xxx alloys met the thermal diffusivity requirements as measured according to ASTME 1461 (2025), and were within 90% of the 7072 control.

[0147] As shown in FIG. 3, each of the tested samples offered galvanic corrosion protection within the performance specification range of the 7072 control, measured according to ASTM G71 (2025). As illustrated, the zinc levels in the prepared 3xxx alloys are controlled to obtain desired galvanic corrosion potential differences.

[0148] Further, as shown in FIGS. 4 and 5, the prepared 3xxx alloys exhibited good mechanical properties.PATENT Attorney Docket No. 108050-1523992

[0149] Finally, as shown in FIG. 6, each of the prepared 3xxx alloys exhibited excellent Olsen height, exceeding the 7072 control.

[0150] Therefore, it should be clear from the prepared 3xxx alloys discussed herein, that the prepared samples exhibited properties in line or exceeding the 7072 control. As discussed above, this is advantageous as such examples illustrate that the 3xxx series aluminum alloys formed herein are well suited for applications requiring high thermal and electrical conductivity.ILLUSTRATIVE ASPECTS

[0151] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4”).

[0152] Aspect 1 : A method of direct chill casting an aluminum alloy product, comprising: casting aluminum alloy in a mold, wherein the aluminum alloy comprises, 0.40 - 1.30 wt. % Si, 0.50 - 2.50 wt. % Fe, 0.10 - 0.40 wt. % Cu, up to 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al; and withdrawing the aluminum alloy from the mold to form an ingot; homogenizing the ingot at a homogenization temperature from 500 °C to 650 °C for a period of time from 1 to 5 hours, and reducing the temperature to a soaking temperature from 350 °C to 550 °C and soaking the ingot for a period of time from 1 to 15 hours; hot rolling the homogenized ingot to produce a hot rolled aluminum alloy; and cold rolling the hot rolled aluminum alloy to produce to an aluminum alloy product.

[0153] Aspect 2: The method of aspect 1, wherein the soaking temperature comprises a temperature from 350 °C to 450 °C.

[0154] Aspect 3: The method of aspect 1 or 2, wherein the direct chill cast aluminum alloy is subjected to soaking for a period of 5 to 15 hours.

[0155] Aspect 4: The method of any one of aspects 1 to 3, further comprising annealing the hot rolled aluminum alloy.

[0156] Aspect 5: The method of any one of aspects 1 to 4, wherein the annealing comprises an annealing temperature from 300 °C to 450 °C for a period of time from 3 to 10 hours.

[0157] Aspect 6: The method of any one of aspects 1 to 5, wherein the annealing comprises a ramped annealing at a heating rate of at least 10° C / h for a period of time from 1 to 5 hours.PATENT Attorney Docket No. 108050-1523992

[0158] Aspect 7: The method of any one of aspects 1 to 6, further comprising tempering the aluminum alloy product.

[0159] Aspect 8: The method of any one of aspects 1 to 7, wherein the cold rolling reduces a thickness of the aluminum alloy product by greater than or about 75% of a thickness of the aluminum alloy product after one or more hot rolling operations.

[0160] Aspect 9: The method of any one of aspects 1 to 8, wherein the aluminum alloy is a 3xxx series aluminum alloy.

[0161] Aspect 10: The method of any one of aspects 1 to 9, wherein the aluminum alloy comprises at least about 40 wt.% recycled content.

[0162] Aspect 11 : The method of any one of aspects 1 to 10, wherein the aluminum alloy product comprises a thermal conductivity greater than or about 180 W / (m*K).

[0163] Aspect 12: A fin stock prepared according to any one or more of aspects 1 to 11.

[0164] Aspect 13: A direct chill cast aluminum alloy product, comprising: 0.40 - 1.30 wt. % Si, 0.50 - 2.50 wt. % Fe, 0.10 - 0.40 wt. % Cu, up to 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al; wherein the direct chill cast aluminum alloy product comprises an electrical conductivity from 40 % to 60 % based on the international annealed copper standard (IACS) and a percent elongation of 1 % to 15 % according to ASTM E8 / E8M-22 testing standards.

[0165] Aspect 14: The product of aspect 13, wherein the direct chill cast aluminum alloy product comprises alpha phase particles and an aluminum alloy matrix, wherein the aluminum alloy matrix comprises less than 0.1 wt.% Mn.

[0166] Aspect 15: The product of aspects 13 or 14, wherein the direct chill cast aluminum alloy product comprises less than 0.1 wt.% Cr.

[0167] Aspect 16: The product of any one of aspects 13 to 15, wherein the direct chill cast aluminum alloy product comprises a combined content of Si and Fe of at least 1.50 wt. %, and wherein the aluminum alloy product comprises a ratio of (Si + Fe): Mn of at least 2.0:1.

[0168] Aspect 17: The product of any one of aspects 13 to 16, wherein the direct chill cast aluminum alloy product comprises a yield strength greater than or about 60 MPa.

[0169] Aspect 18: The product of any one of aspects 13 to 17, wherein the direct chill cast aluminum alloy product comprises an ultimate tensile strength greater than or about 130 MPa.PATENT Attorney Docket No. 108050-1523992

[0170] Aspect 19: The product of any one of aspects 13 to 18, wherein the direct chill cast aluminum alloy product comprises a thermal conductivity greater than 180 W / (m*K).

[0171] Aspect 20: A fin stock comprising the direct chill cast aluminum alloy product of any one of claims 13 to 18 or method 1 to 11.

[0172] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

PATENT Attorney Docket No. 108050-1523992WHAT IS CLAIMED IS:

1. A method of direct chill casting an aluminum alloy product, comprising: Casting an aluminum alloy in a mold, wherein the aluminum alloy comprises,0.40 - 1.30 wt. % Si,0.50 - 2.50 wt. % Fe,0.10 - 0.40 wt. % Cu,up to 1.00 wt. % Mn,0.40 - 0.80 wt. % Mg,up to 3.50 wt. % Zn,up to 0.20 wt. % Cr,up to 0.20 wt. % Ti,up to 0.15 wt. % of impurities, andthe remainder Al; andwithdrawing the aluminum alloy from the mold to form an ingot; homogenizing the ingot at a homogenization temperature from 500 °C to 650 °C for a period of time from 1 to 5 hours, and reducing the temperature to a soaking temperature from 350 °C to 550 °C and soaking the ingot for a period of time from 1 to 15 hours;hot rolling the homogenized ingot to produce a hot rolled aluminum alloy; and cold rolling the hot rolled aluminum alloy to produce to an aluminum alloy product.

2. The method of claim 1, wherein the soaking temperature comprises a temperature from 350 °C to 450 °C.

3. The method of claim 1, wherein the direct chill cast aluminum alloy is subjected to soaking for a period of 5 to 15 hours.

4. The method of claim 1, further comprising annealing the hot rolled aluminum alloy.

5. The method of claim 4, wherein the annealing comprises an annealing temperature from 300 °C to 450 °C for a period of time from 3 to 10 hours.

6. The method of claim 4, wherein the annealing comprises a ramped annealing at a heating rate of at least 10° C / h for a period of time from 1 to 5 hours.PATENT Attorney Docket No. 108050-15239927. The method of claim 4, further comprising tempering the aluminum alloy product.

8. The method of claim 1, wherein the cold rolling reduces a thickness of the aluminum alloy product by greater than or about 75% of a thickness of the aluminum alloy product after one or more hot rolling operations.

9. The method of claim 1, wherein the aluminum alloy is a 3xxx series aluminum alloy.

10. The method of claim 1, wherein the aluminum alloy comprises at least about 40 wt.% recycled content.

11. The method of claim 1, wherein the aluminum alloy product comprises a thermal conductivity greater than or about 180 W / (m*K).

12. A fin stock prepared according to the method of claim 1.

13. A direct chill cast aluminum alloy product, comprising:0.40 - 1.30 wt. % Si,0.50 - 2.50 wt. % Fe,0.10 - 0.40 wt. % Cu,up to 1.00 wt. % Mn,0.40 - 0.80 wt. % Mg,up to 3.50 wt. % Zn,up to 0.20 wt. % Cr,up to 0.20 wt. % Ti,up to 0.15 wt. % of impurities, andthe remainder Al;wherein the direct chill cast aluminum alloy product comprises an electrical conductivity from 40 % to 60 % based on the international annealed copper standard (IACS) and a percent elongation of 1 % to 15 % according to ASTM E8 / E8M-22 testing standards.

14. The direct chill cast aluminum alloy product of claim 13, wherein the direct chill cast aluminum alloy product comprises alpha phase particles and an aluminum alloy matrix, wherein the aluminum alloy matrix comprises less than 0.1 wt.% Mn.PATENT Attorney Docket No. 108050-152399215. The direct chill cast aluminum alloy product of claim 13, wherein the direct chill cast aluminum alloy product comprises less than 0.1 wt.% Cr.

16. The direct chill cast aluminum alloy product of claim 13, wherein the direct chill cast aluminum alloy product comprises a combined content of Si and Fe of at least 1.50 wt. %, and wherein the aluminum alloy product comprises a ratio of (Si + Fe): Mn of at least 2.0:1.

17. The direct chill cast aluminum alloy product of claim 13, wherein the direct chill cast aluminum alloy product comprises a yield strength greater than or about 60 MPa.

18. The direct chill cast aluminum alloy product of claim 13, wherein the direct chill cast aluminum alloy product comprises an ultimate tensile strength greater than or about 130 MPa.

19. The direct chill cast aluminum alloy product of claim 13, wherein the direct chill cast aluminum alloy product comprises a thermal conductivity greater than 180 W / (m*K).

20. A fin stock comprising the direct chill cast aluminum alloy product of claim

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