Recycled Aluminum Alloy Composition for Impact-Extruded Containers
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Solution Overview
Problem
The existing impact extrusion process for manufacturing aluminum containers is limited by the requirement for very pure, soft aluminum alloys, making it impractical to use recycled materials like aluminum alloys 3104, 3105, or 3004.
Innovation Solution
A novel aluminum alloy is developed by blending recycled 3105 or 3104 aluminum with relatively pure 1070 aluminum, along with the addition of titanium boride, to create a unique alloy suitable for impact extrusion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If very pure virgin aluminum (1070 or 1050) is used in impact extrusion, then the container strength and processability are improved, but the manufacturing cost increases and natural resources are consumed
Solution Approach 1:
The patent changes the chemical composition parameters of the aluminum alloy by incorporating recycled aluminum (3003, 3104, or 3105) containing specific amounts of alloying elements (Si: 0.03-0.60%, Fe: 0.03-0.60%, Cu: 0.03-0.30%, Mn: 0.03-0.30%, Mg: 0.03-0.30%, Zn: 0.03-0.30%). This parameter modification allows the use of recycled materials while maintaining the mechanical properties required for impact extrusion container manufacturing
Solution Approach 2:
The patent creates a composite aluminum alloy system by combining recycled aluminum containing various alloying elements with pure aluminum (1070 or 1050). The resulting composite material (designated as 107X or 105X alloy) integrates the benefits of both pure aluminum (ductility, formability) and recycled aluminum (cost-effectiveness, sustainability) while meeting strength requirements
2Ease of manufacture
If recycled aluminum alloys (3104, 3105, 3004) are used in impact extrusion, then the environmental sustainability and cost are improved, but the container strength and processability deteriorate
Solution Approach 1:
The patent modifies the alloy composition parameters by strictly controlling the content of alloying elements from recycled aluminum. The specified ranges (Si: 0.03-0.60%, Fe: 0.03-0.60%, Cu: 0.03-0.30%, Mn: 0.03-0.30%, Mg: 0.03-0.30%, Zn: 0.03-0.30%) ensure that harmful impurities are limited while maintaining cost benefits and sustainability advantages of recycled materials
Solution Approach 2:
The patent applies local quality control by differentiating the acceptable ranges of different alloying elements based on their specific effects on material properties. For example, Si and Fe are allowed up to 0.60% while Cu, Mn, Mg, and Zn are limited to 0.30%, reflecting their different impacts on strength, ductility, and formability
3Strength
If thicker gage and heavier materials are used in impact extruded containers, then the container strength and pressure retention are improved, but the container weight and manufacturing cost increase
Solution Approach 1:
The patent optimizes the alloy composition parameters to achieve the desired strength-to-weight ratio. By carefully controlling the content of alloying elements within specific ranges, the material gains sufficient strength for pressure retention while avoiding excessive weight gain that would occur with thicker gauges
Solution Approach 2:
The composite aluminum alloy (107X or 105X) combines the advantages of pure aluminum (lightweight, ductile) with controlled amounts of alloying elements (strength enhancement). This composite structure provides adequate pressure retention capability without requiring increased wall thickness, thereby maintaining lightweight characteristics
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.