Recycled Aluminum Slug Composition for Impact-Extruded Containers
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Solution Overview
Problem
The existing impact extrusion process for manufacturing aluminum containers requires high-purity virgin aluminum, making it infeasible to use recycled aluminum alloys like 3104, 3004, 3003, 3013, and 3105 due to metallurgical challenges, which limits the use of recycled materials and increases manufacturing costs.
Innovation Solution
A novel alloy composition is developed by blending recycled aluminum alloys (3104, 3004, 3003, 3105) with relatively pure aluminum (1070) and adding titanium boride, and a manufacturing process is used to create a slug suitable for impact extrusion, addressing metallurgical challenges and enabling the use of recycled materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-purity virgin aluminum is used in impact extrusion, then the container strength and process reliability are improved, but the manufacturing cost increases and recycled materials cannot be utilized
Solution Approach 1:
The invention changes the chemical composition parameters of the aluminum alloy by incorporating specific amounts of alloying elements (0.01-0.06% Fe, 0.01-0.05% Si, 0.01-0.03% Cu, 0.01-0.04% Mn, 0.01-0.03% Mg, 0.01-0.02% Zn, 0.01-0.02% Cr, 0.01-0.02% Ti) into the recycled aluminum alloy, transforming it from an unsuitable material to one that meets impact extrusion requirements
Solution Approach 2:
The invention creates a composite aluminum alloy system by combining recycled aluminum (3104, 3004, 3003, 3105, or 3013) with controlled additions of alloying elements, producing a multi-component material that exhibits both recyclability and the mechanical properties needed for impact extrusion
2Ease of manufacture
If recycled aluminum alloys are used, then manufacturing cost decreases and resource conservation is improved, but the container strength and process reliability deteriorate due to metallurgical challenges
Solution Approach 1:
The invention modifies the metallurgical parameters of recycled aluminum by controlling the concentration ranges of alloying elements, ensuring the material achieves the necessary ductility, strength, and formability for impact extrusion while maintaining cost advantages
Solution Approach 2:
The invention applies different alloying strategies to different recycled aluminum types (3104, 3004, 3003, 3105, 3013), tailoring the composition to the specific characteristics of each base alloy to optimize both performance and recyclability
3Strength
If thicker gage and heavier materials are used to achieve high strength, then container strength is improved, but the container weight increases and productivity decreases
Solution Approach 1:
The invention develops a strengthened aluminum alloy through controlled alloying that achieves high strength-to-weight ratio, allowing thin-walled containers to maintain structural integrity without requiring increased material thickness or weight
Solution Approach 2:
The invention optimizes the alloy composition parameters to enhance mechanical properties (yield strength, ultimate tensile strength, elongation) enabling the production of lightweight containers with adequate strength through material property improvement rather than geometric thickening
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in lightweight yet strong aluminum containers with improved strength-to-weight ratio, burst pressures, dent resistance, and reduced metal content, while utilizing recycled materials to conserve resources and lower production costs.
Implementation Method 1
The alloy may include about 0.01% to about 0.06% Fe, about 0.01% to about 0.05% Si, about 0.01% to about 0.03% Cu, about 0.01% to about 0.04% Mn, about 0.01% to about 0.03% Mg, about 0.01% to about 0.02% Zn, about 0.01% to about 0.02% Cr, and about 0.01% to about 0.02% Ti
Data Source
AI summary
Novel recycled 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 recycled aluminum for use in the impact extraction process.