Impact-Extrusion Aluminum Alloy Using Recycled Scrap Blends
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Solution Overview
Problem
The challenge is to develop a method for using recycled aluminum alloys in impact extrusion processes to manufacture lightweight yet strong aluminum containers, as traditional methods require nearly pure aluminum and cannot effectively utilize scrap materials like 3104, 3004, 3003, 3013, and 3105 alloys.
Innovation Solution
A novel aluminum alloy composition is created by blending recycled 3105 or 3104 aluminum with relatively pure 1070 aluminum, along with other metals like titanium boride, to form a slug that can be impact extruded into containers with enhanced strength-to-weight ratio and resistance to pressure, deformation, and scratching, while reducing material usage and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If recycled aluminum alloys (3104, 3004, 3003, 3013, 3105) are used in impact extrusion, then material cost and environmental impact are improved, but the manufacturing process becomes infeasible due to metallurgical requirements
Solution Approach 1:
The patent modifies the chemical composition parameters of the aluminum alloy by adding specific elements (0.01-0.05% Fe, 0.01-0.03% Si, 0.01-0.02% Cu, 0.01-0.02% Mn, 0.01-0.02% Mg, 0.01-0.02% Zn, 0.01-0.02% Cr, 0.01-0.02% Ti) to enable recycled aluminum alloys to meet the metallurgical requirements for impact extrusion, transforming the material properties to achieve both recyclability and process feasibility
Solution Approach 2:
The patent creates a composite aluminum alloy system that combines recycled aluminum base material with multiple alloying elements, forming a new composite material that retains the recyclability benefits while achieving the mechanical properties and metallurgical characteristics necessary for successful impact extrusion processing
2Reliability
If nearly pure aluminum (1070, 1050) is used in impact extrusion, then the impact extrusion process works reliably, but the containers become heavier and more expensive
Solution Approach 1:
The patent changes the compositional parameters from nearly pure aluminum (99.5% Al) to a controlled alloy composition with multiple elements at 0.01-0.05% levels, which enables the use of thinner gauge materials while maintaining process reliability and container performance, thereby reducing overall container weight
Solution Approach 2:
The patent enables the use of recycled aluminum materials that are typically considered lower-grade or scrap materials, transforming them into suitable feedstock for impact extrusion, which reduces material cost and weight compared to using virgin pure aluminum
3Strength
If thicker gage and heavier materials are used in impact extruded containers, then strength and pressure resistance are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent optimizes the alloy composition parameters to achieve enhanced strength-to-weight ratio, allowing the use of thinner gauge materials that meet strength and pressure resistance requirements at lower manufacturing cost
Solution Approach 2:
The patent applies specific alloying elements at controlled concentrations to achieve localized property enhancements in the aluminum alloy, providing the necessary strength and durability characteristics in critical areas while maintaining overall cost-effectiveness
Data Source
AI summary
Novel aluminum alloys are provided for use in an impact extrusion manufacturing process to create shaped containers and other articles of manufacture. In one embodiment blends of recycled scrap aluminum are used in conjunction with relatively pure aluminum to create novel compositions which may be formed and shaped in an environmentally friendly process. Other embodiments include methods for manufacturing a slug material comprising mixtures of aluminum alloys for use in the impact extraction process, a container manufactured using the aluminum alloy in an impact extrusion process, and the container, wherein the material of the container is the aluminum alloy.