EP2822716A1 - Alliages d'aluminium améliorés contenant du magnésium, du silicium, du manganèse, du fer et du cuivre, et procédés de production de ceux-ci - Google Patents

Alliages d'aluminium améliorés contenant du magnésium, du silicium, du manganèse, du fer et du cuivre, et procédés de production de ceux-ci

Info

Publication number
EP2822716A1
EP2822716A1 EP13757630.2A EP13757630A EP2822716A1 EP 2822716 A1 EP2822716 A1 EP 2822716A1 EP 13757630 A EP13757630 A EP 13757630A EP 2822716 A1 EP2822716 A1 EP 2822716A1
Authority
EP
European Patent Office
Prior art keywords
aluminum alloy
cold
cold working
alloy body
aluminum
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13757630.2A
Other languages
German (de)
English (en)
Other versions
EP2822716A4 (fr
Inventor
Rajeev KAMAT
John M. Newman
Ralph R. Sawtell
Jen C. Lin
Darl G. Boysel
Gary H. Bray
James Daniel Bryant
Brett P. Conner
Mario Greco
Gino Norman IASELLA
Lynette M. Karabin
David J. MCNEISH
Shawn J. Murtha
Roberto J. Rioja
Shawn P. Sullivan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Howmet Aerospace Inc
Original Assignee
Alcoa Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Inc filed Critical Alcoa Inc
Publication of EP2822716A1 publication Critical patent/EP2822716A1/fr
Publication of EP2822716A4 publication Critical patent/EP2822716A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/18—Alloys based on aluminium with copper as the next major constituent with zinc
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent

Definitions

  • Aluminum alloys are useful in a variety of applications. However, improving one property of an aluminum alloy without degrading another property is elusive, For example, it is difficult to increase the strength of an alloy without decreasing the toughness of an alloy. Other properties of interest for aluminum alloys include corrosion resistance and fatigue crack growth resistance, to name two.
  • the present patent application relates to improved wrought, heat treatable aluminum alloys, and methods for producing the same.
  • the present patent application relates to improved wrought, heat treatable aluminum alloy products having at tailored amounts of Mg, Si, Fe, Cu, optionally with Mn, and optionally Zn (the "new HT aluminum alloys"), and methods for producing the same.
  • the new HT aluminum alloy products achieve an improved combination of properties due to, for example, the post- solutionizing cold work and post-cold-working thermal treatments, as described in further detail below.
  • new HT aluminum alloys are aluminum alloys having 0.2 - 2.0 wt. % Mg, 0.1 - 1.5 wt.
  • a new HT aluminum alloy body is cast (10), after which it is homogenized (1 1) and then hot rolled to an intermediate gauge (12), Next, the new HT aluminum alloy body is cold rolled (13) to final gauge, after which it is solution heat treated and quenched (14).
  • solutionizing means heating an aluminum alloy body to a suitable temperature, generally above the solvus temperature, holding at that temperature long enough to allow soluble elements to enter into solid solution, and cooling rapidly enough to hold the elements in solid solution.
  • the solid solution formed at high temperature may be retained in a supersaturated state by cooling with sufficient rapidity to restrict the precipitation of the solute atoms as coarse, incoherent particles.
  • the new HT aluminum alloy body may be optionally stretched a small amount (e.g., 1-5%) for flatness (15), thermally treated (16) and optionally subjected to final treatment practices (17).
  • FIG. 1 is consistent with a process path for producing aluminum alloys in a T6 temper (the T6 temper is defined later in this patent application).
  • FIG. 2a One embodiment of a new process for producing new HT aluminum alloy products is illustrated in FIG. 2a.
  • a new HT alivminum alloy body is prepared for post- so lutionizing cold work (100), after which it is cold worked (200), and then thermally treated (300).
  • the new process may also include optional final treatment(s) (400), as described in further detail below.
  • Post-solutionizing cold work and the like means cold working of an aluminum alloy body after solutionizing.
  • the amount of post-solutionizing cold work applied to the new HT aluminum alloy body is generally at least 25%, such as more than 50% cold work.
  • the new HT aluminum alloy body may realize improved properties, as described in further detail below. For example, strength increases of 5- 25%, or more, may be realized relative to conventional aluminum alloy products in the T6 temper, and in a fraction of the time required to process those conventional aluminum alloy products to the T6 temper (e.g., 10%-90% faster than T6 temper processed alloys).
  • the new HT aluminum alloy body may also realize good ductility, generally realizing an elongation of more than 4%, such as elongations of 6-15%, or higher.
  • Other properties may also be maintained and/or improved (e.g., fracture toughness, corrosion resistance, fatigue crack growth resistance, appearance).
  • the new process includes preparing an aluminum alloy body for post-solutionizing cold work (100).
  • the aluminum alloy body may be prepared for post- solutionizing cold work (100) in a variety of manners, including the use of conventional semi- continuous casting methods (e.g., direct chill casting of ingot) and continuous casting methods (e.g., twin-roll casting).
  • the preparing step (100) generally comprises placing the aluminum alloy body in a form suitable for the cold working (120) and solutionizing the aluminum alloy body (140).
  • the placing step (120) and solutionizing step (140) may occur sequentially or concomitant to one another.
  • the preparing step (100) comprises a semi-continuous casting method.
  • the placing step (120) includes casting the aluminum alloy body (122) (e.g., in the form of an ingot or billet), homogenizing the aluminum alloy body (124), hot working the aluminum alloy body (126), and optionally cold working the aluminum alloy body (128), After the placing step (120), the solutionizing step (140) is completed. Similar steps may be completed using continuous casting operations, although the aluminum alloy body would not be in the form of an ingot / billet after casting (120).
  • a preparing step (100) includes casting the aluminum alloy body (122), homogenizing the aluminum alloy body (124) and hot working the aluminum alloy body (126).
  • the hot working step (126) may be completed to place soluble elements in solid solution, after which the aluminum alloy body is quenched (not illustrated), thereby resulting in the solutionizing step (140).
  • This embodiment may be applicable to press-quenched products (e.g., extrusions) and hot rolled products that are quenched after hot rolling, among others.
  • the preparing step (100) comprises a continuous casting method, such as belt casting, rod casting, twin roll casting, twin belt casting (e.g., Hazelett casting), drag casting, and block casting, among others.
  • a continuous casting method such as belt casting, rod casting, twin roll casting, twin belt casting (e.g., Hazelett casting), drag casting, and block casting, among others.
  • FIG. 6a One embodiment of a preparing step (100) employing a continuous casting methodology is illustrated in FIG. 6a.
  • the aluminum alloy body is cast and solutionized at about the same time (142), i.e., concomitant to one another.
  • the casting places the aluminum alloy body in a form sufficient to cold work, When the solidification rate during casting is sufficiently rapid, the aluminum alloy body is also solutionized.
  • the casting / solutionizing step (142) may include quenching of the aluminum alloy body after casting (not illustrated).
  • This embodiment may be applicable to twin-roll casting processes, among other casting processes.
  • Some twin-roll casting apparatus and processes capable of completing the process of FIG, 6a are described in U.S. Patent No, 7,182,825, U.S. Patent No. 7, 125,612, U.S. Patent No. 7,503,378, and U.S. Patent No, 6,672,368, and are described relative to FIGS. 6b- 1 through 6x, below.
  • a preparing step (100) includes casting the aluminum alloy body (122) and, after the casting step (122), then solutionizing the aluminum alloy body (140),
  • the placing step (120) comprises the casting (122), This embodiment is applicable to twin-roll casting processes, among other casting processes.
  • a preparing step (100) includes casting the aluminum alloy body (122), hot working the aluminum alloy body (126), and optionally cold working the aluminum alloy body (128).
  • the placing step (120) includes the casting (122), the hot working (126), and optional cold working (128) steps. After the placing step (120), the solutionizing step (140) is completed. This embodiment may be applicable to continuous casting processes.
  • the cold working (200) and thermal treatment step ( 00) are completed continuously.
  • a solutionized aluminum alloy body may enter the cold working operation at ambient conditions.
  • the cold worked aluminum alloy body could be immediately thermally treated (300) after cold working (e.g., in-line) (e,g,, the thermally treating step (300) is completed concomitant to the cold working step (200)).
  • such thermal treatments could occur proximal the outlet of the cold working apparatus, or in a separate heating apparatus connected to the cold working apparatus. This could increase productivity.
  • the preparing step (100) and cold working step (200) are completed continuously (e.g., when a continuously casting apparatus is used, and such that the continuously as-cast aluminum alloy body may immediately and continuously proceed to the cold working step (200), such as shown in FIG. 6a.
  • the casting / solutionizing step (142) may include quenching the aluminum alloy body to a suitable cold working temperature (e.g., less than 150°F),
  • all three of the preparing step (100), the cold working step (200) and the thermal treatment step (300) are completed continuously.
  • the preparing step (100) generally comprises solutionizing of the aluminum alloy body.
  • solutionizing includes quenching (not illustrated) of the aluminum alloy body, which quenching may be accomplished via a liquid (e.g., via an aqueous or organic solution), a gas (e.g., air cooling), or even a solid (e.g., cooled solids on one or more sides of the aluminum alloy body).
  • the quenching step includes contacting the aluminum alloy body with a liquid or a gas. In some of these embodiments, the quenching occurs , in the absence of hot working and/or cold working of the aluminum alloy body.
  • the quenching may occur by immersion, spraying and/or jet drying, among other techniques, and in the absence of deformation of the aluminum alloy body.
  • the solutionizing step is generally the last step of the preparing step and immediately precedes the cold working step,
  • preparing steps (100) can be used to prepare an aluminum alloy body for post-solutionizing cold work (e.g., powder metallurgy methods), and that such other preparing steps fall within the scope of the preparing step (100) so long as they place the aluminum alloy body in a form suitable for cold working (120) and solutionize the aluminum alloy body (140), and irrespective of whether these placing (120) and solutionizing (140) steps occur concomitantly (e.g., contemporaneously) or sequentially, and irrespective of whether the placing step (120) occurs before the solutionizing step (140), or vice- versa.
  • Continuous Casting Embodiments a. Twin-Roll Continuous Casting ⁇ Continuous Casting and Solutionizing .
  • the aluminum alloy bodies of the present disclosure may be prepared for post-solutionizing cold work by being continuously cast between a horizontal two- roll or two-belt caster, wherein the solutionizing occurs concomitant to the continuous casting (e.g., due to the continuous casting methodology),
  • the aluminum alloy bodies may be continuously cast by being juxtaposed and in communication with a pair of internally cooled rolls.
  • FIGS. 6b- 1 to 6b-2 one embodiment of a horizontal twin-roll continuous casting apparatus is illustrated. This apparatus uses a pair of counter- rotating cooled rolls Ri and R 2 rotating in the directions of the arrows A[ and A ⁇ , respectively.
  • the term horizontal means that the cast strip (S) is produced in a horizontal orientation or at an angle of plus or minus 30 degrees from horizontal.
  • a feed tip T which may be made from a ceramic material, may distribute molten metal in the direction of the arrow. Gaps Gi and G 2 between the feed tip T and the respective rolls Rj and R 2 may be maintained as small as possible; however, contact between the tip T and the rolls i and R 2 should be avoided. Without wishing to be bound by the theory, it is believed that maintaining small gaps aids to prevent molten metal from leaking out and to minimize the exposure of the molten metal to the atmosphere along the Ri and R 2 .
  • a suitable dimension of the gaps G] and G 2 may be 0.01 inch (0.254 mm).
  • a plane L through the centerline of the rolls R] and R 2 passes through a region of minimum clearance between the rolls Ri and R 2 referred to as the roll nip N,
  • the molten metal M may directly contact the cooled rolls Ri and R 2 at regions 2-6 and 4- 6, respectively. Upon contact with the rolls R
  • the cooling metal produces an upper shell 6-6 of solidified metal adjacent the roll R ⁇ and a lower shell 8-6 of solidified metal adjacent to the roll R 2 .
  • the thickness of the shells 6-6 and 8-6 increases as the metal M advances towards the nip N. Large dendrites 10-6 of solidified metal (not shown to scale) may be produced at the interfaces between each of the upper and lower shells 6-6 and 8-6 and the molten metal M.
  • the large dendrites 10-6 may be broken and dragged into a center portion 12-6 of the slower moving flow of the molten metal M and may be carried in the direction of arrows Q and ( 3 ⁇ 4. The dragging action of the flow can cause the large dendrites 10-6 to be broken further into smaller dendrites 14-6 (not shown to scale).
  • the metal M is semi-solid and may include a solid component (the solidified small dendrites 14-6) and a molten metal component.
  • the metal M in the region 16-6 may have a mushy consistency due in part to the dispersion of the small dendrites 14-6 therein.
  • the central portion 12-6 may be a solid central layer, or region, 18-6 containing the small dendrites 14-6 sandwiched between the upper shell 6-6 and the lower shell 8-6.
  • the small dendrites 14-6 may be 20 microns to 50 microns in size and have a generally globular shape.
  • the three layers, or regions of a single cast metal sheet/layer, of the upper and lower shells 6-6 and 8-6 and the solidified central layer 18-6 constitute a solid cast strip 20-6.
  • the aluminum alloy strip 20-6 includes a first layer, or region, of an aluminum alloy and a second layer, or region, of the aluminum alloy (corresponding to the shells 6-6 and 8-6) with an intermediate layer, or region, (the solidified central layer 18-6) therebetween.
  • the solid central layer, or region, 18-6 may constitute 20 percent to 30 percent of the total thickness of the strip 20-6,
  • the concentration of the small dendrites 14-6 may be higher in the solid central layer 18-6 of the strip 20-6 than in the semi-solid region 16-6, of the flow, or the central portion 12-6,
  • the molten aluminum alloy may have an initial concentration of alloying elements including peritectic forming alloying elements and eutectic forming alloying elements, such as any of the alloying elements described in the Composition section (Section G), below.
  • alloying elements that are peritectic formers with aluminum include Ti, V, Zr and Cr.
  • Examples of eutectic formers with aluminum include Si, Fe, Ni, Zn, Mg, Cu, Li and Mn.
  • the aluminum alloy body includes 0.2 - 2.0 wt % Mg, 0.1 - 1.5 wt. % Si.
  • dendrites typically have a lower concentration of eutectic formers than the surrounding mother melt and higher concentration of peritectic formers.
  • the small dendrites 14-6 are thus partially depleted of eutectic formers while the molten metal surrounding the small dendrites is somewhat enriched in eutectic formers, Consequently, the solid central layer, or region, 18-6 of the strip 20-6, which contains a large population of dendrites, is depleted of eutectic formers and is enriched in peritectic formers in comparison to the concentration of the eutectic formers and the peritectic formers in the upper shell 6-6 and the lower shell 8-6.
  • an alloy comprises a larger amount (higher average through thickness concentration in that region) of at least one of Si and Mg in the upper region or lower region of the alloy product as compared to the amount of Si and/or Mg at the centerline of the aluminum alloy product, wherein the concentration in these regions is determined using the Concentration Profile Procedure, described below.
  • an alloy comprises a higher concentration of both Si and Mg in the upper region or lower region of the alloy product. In one embodiment, an alloy comprises a higher concentration of at least one of Si and Mg in both the upper region and the lower region of the alloy product, hi one embodiment, an alloy comprises higher concentration of both Si and Mg in both the upper region and the lower region of the alloy product, In one embodiment, the alloy comprises at least a 1% higher Si and/or Mg concentration (average concentration in the upper or lower region, as applicable) relative to the Si and/or Mg concentration at the centerline of the product, In one embodiment, the alloy comprises at least a 3% higher Si and/or Mg concentration (average concentration in the upper or lower region, as applicable) relative to the Si and/or Mg concentration at the centerline of the product.
  • the alloy comprises at least a 5% higher Si and/or Mg concentration (average concentration in the upper or lower region, as applicable) relative to the Si and/or Mg concentration at the centerline of the product. In one embodiment, the alloy comprises at least a 7% higher Si and/or Mg concentration (average concentration in the upper or lower region, as applicable) relative to the Si and/or Mg concentration at the centerline of the product. In one embodiment, the alloy comprises at least a 9% higher Si and/or Mg concentration (average concentration in the upper or lower region, as applicable) relative to the Si and/or Mg concentration at the centerline of the product.
  • a JEOL JXA8600 Superprobe is used to obtain through-thickness composition profiles in the prepared aluminum sheet samples.
  • the Superprobe has four Wave Dispersive Spectrometer (WDS) detectors, two of which are gas flow (P-10) counters, and the others being Xe-gas sealed counters.
  • WDS Wave Dispersive Spectrometer
  • the detection range of elements is from Beryllium (Be) to Uranium (U).
  • the quantitative analysis detection limit is 0.02 wt%.
  • the instrument is equipped with Geller Microanalytical Dspec/Dquant automation which allows stage control and unattended quantitative and qualitative analysis.
  • the Superprobe is set to the following conditions: accelerating voltage 15kV, beam intensity ⁇ , defocus electron beam to an appropriate size such that a minimum of 13 different sections of the sample can be measured (e.g., defocused to ⁇ ⁇ ⁇ for a 0.060 inch thick specimen), and exposure time for each element is 10 seconds. Background correction was done for the sample surface at three random locations with a counting time of 5 seconds on positive and negative backgrounds.
  • any of the following elements may be analyzed, as appropriate: Mn, ' Cu, Mg, Zn, Si, and Fe.
  • Si is analyzed by a PET diffracting crystal with a gas flow (P-10) counter; Fe, Cu, Zn, and Mn are by a LIF diffracting crystal with a Xe-gas sealed counter; Mg is analyzed by a TAP diffracting crystal with a gas flow (P-10) counter.
  • the counting time for each element is 10 seconds. This linescan is repeated 30 times down the length of the sheet sample. At any one location of the sample, the reported composition of each element should be the averaged value of 30 measurements at the same thickness locations
  • concentration in each of these regions excluding (i) the edge (surface) of the upper region and the lower region and (ii) the transition zone between the center region and each of the upper region and the lower region.
  • concentration of an element must be measured at a minimum of four' (4) different locations in each of the upper and lower regions to determine the average concentration of such element in each of those regions.
  • serial sectioning is used wherein a section (through thickness) is obtained by (i) machining for samples having a thickness of 0.030 or higher, or (ii) chemical thinning via an appropriate chemical etchant for samples having a thiclaiess of less than 0.030. At least 13 different through thicloiess samples are obtained and such that a centerline sample is always produced. Each of samples is then analyzed for its Li content by atomic absorption.
  • the rolls Ri and R 2 may serve as heat sinks for the heat of the molten metal M.
  • heat may be transferred from the molten metal M to the rolls Ri and R 2 in uniform manner to ensure uniformity in the surface of the cast strip 20-6.
  • and R 2 may be made from steel or copper and may be textured and may include surface irregularities (not shown) which may contact the molten metal M. The surface irregularities may serve to increase the heat transfer from the surfaces Di and D 2 and, by imposing a controlled degree of non-uniformity in the surfaces Dj and D 2 , result in uniform heat transfer across the surfaces D] and D 2 .
  • the surface irregularities may be in the form of grooves, dimples, knurls or other structures and may be spaced apart in a regular pattern of 20 to 120 surface irregularities per inch, or about 60 irregularities per inch.
  • the surface irregularities may have a height ranging from 5 microns to 50 microns, or alternatively about 30 microns.
  • the rolls Ri and R 2 may be coated with a material to enhance separation of the cast strip from the rolls Rj and R 2 such as chromium or nickel.
  • the control, maintenance and selection of the appropriate speed of the rolls Ri and R 2 may impact the ability to continuously cast strips using the present apparatus and methods.
  • the roll speed determines the speed that the molten metal M advances towards the nip N. If the speed is too slow, the large dendrites 10-6 will not experience sufficient forces to become entrained in the central portion 12-6 and break into the small dendrites 14-6.
  • the roll speed may be selected such that a freeze front, or point of complete solidification, of the molten metal M may form at the nip N.
  • the present casting apparatus and methods may be suited for operation at high speeds such as those ranging from 25 to 400 feet per minute; alternatively from 50 to 400 feet per minute; alternatively from 100 to 400 feet per minute; and alternatively from 150 to 300 feet per minute.
  • the linear rate per unit area that molten aluminum is delivered to the rolls Ri and R 2 may be less than the speed of the rolls Ri and R 2 or about one quarter of the roll speed.
  • High-speed continuous casting may be achievable with the presently disclosed apparatus and methods, at least in part, because the textured surfaces Di and D 2 ensure uniform heat transfer from the molten metal M. Due to such high casting speeds and associated rapid solidification rates, the soluble constituents may be substantially retained in solid solution, i.e., the solutionizing step may occur concomitant to the casting step.
  • the roll separating force may be a parameter in using the presently disclosed casting apparatus and methods.
  • One benefit of the presently disclosed continuous casting apparatus and methods may be that solid strip is not produced until the metal reaches the nip N.
  • the thickness is determined by the dimension of the nip N between the rolls Ri and R 2 .
  • the roll separating force may be sufficiently great to squeeze molten metal upstream and away from the nip N. Excessive molten metal passing through the nip N may cause the layers of the upper and lower shells 6-6 and 8-6 and the solid central region 18-6 to fall away from each other and become misaligned. Insufficient molten metal reaching the nip N may cause the strip to form prematurely.
  • a prematurely formed strip may be deformed by the rolls Ri and R 2 and experience centerline segregation. Suitable roll separating forces may range from 25 to 300 pounds per inch of width cast, or 100 pounds per inch of width cast. In general, slower casting speeds may be needed when casting thicker gauge strips in order to remove the heat. Such slower casting speeds do not result in excessive roll separating forces because fully solid aluminum strip is not produced upstream of the nip.
  • the grains in the aluminum alloy strip 20-6 are substantially undeformed because the force applied by the rolls is low (300 pounds per inch of width or less). Furthermore, since the strip 20-6 is not solid until it reaches the nip N; it will not be "hot rolled".
  • the strip 20-6 does not receive a thermo-mechanical treatment due to the casting process itself, and when not subsequently hot rolled, the grains in the strip 20-6 will generally be substantially undeformed, retaining their initial structure achieved upon solidification, i.e. an equiaxial structure, such as globular, prior to the cold working step (200).
  • Thin gauge aluminum strip products may be cast using the presently described continuously casting apparatus and methods.
  • Aluminum alloy strips may be produced at thicknesses of 0.100 inch or less at casting speeds ranging from 25 to 400 feet per minute; alternatively from 50 to 400 feet per minute; and alternatively from 100 to 400 feet per minute, Thicker gauge aluminum alloy strips may also be produced using the presently disclosed methods, for example at a thickness of 0.249 inch, or less.
  • the continuously cast strips generally have a thickness of a sheet or foil product, per aluminum association standards.
  • and D 2 may heat up during casting and are may be prone to oxidation at elevated temperatures. Non-uniform oxidation of the roll surfaces during casting can change the heat transfer properties of the rolls Rj and R 2 . Hence, the roll surfaces Di and D 2 may be oxidized prior to use to minimize changes thereof during casting, It may be beneficial to brush the roll surfaces Dj and D 2 from time-to-time, or continuously, to remove debris which may build up during casting of aluminum and aluminum alloys. Small pieces of the cast strip may break free from the strip S and adhere to the roll surfaces Di and D 2 . These small pieces of aluminum alloy strip may be prone to oxidation, which may result in non-uniformity in the heat transfer properties of the roll surfaces Di and D 2 . Brushing of the roll surfaces Dj and D 2 avoids the non-uniformity problems from debris which may collect on the roll surfaces Di and D 2 .
  • Continuous casting of aluminum alloys may be achieved by initially selecting the desired dimension of the nip N corresponding to the desired gauge of the strip S, The speed of the rolls Ri and R 2 may be increased to a desired production rate or to a speed which is less than the speed which causes the roll separating force increases to a level which indicates that rolling is occurring between the rolls Ri and R 2 , Casting at the rates contemplated by the present invention (i.e. 25 to 400 feet per minute) solidifies the aluminum alloy strip about 1000 times faster than aluminum alloy cast as an ingot cast and improves the properties of the strip over aluminum alloys cast as an ingot.
  • the rate at which the molten metal is cooled may be selected to achieve rapid solidification of the outer regions of the metal. Indeed, the cooling of the outer regions of metal may occur at a rate of at least 1000 degrees centigrade per second.
  • the solutionizing step may occur concomitant to the casting step.
  • the amount of solute retained in solid solution is related to an electrical conductivity of an alloy, with lower electrical conductivity values translated to more solute in solid solution.
  • an aluminum alloy body made by the continuous casting processes disclosed above may realize low electrical conductivity values.
  • an aluminum alloy processed according to such methods is within 50% of the theoretical minimum electrical conductivity of the alloy.
  • an aluminum alloy body made by the continuous casting processes disclosed above is within 40% of the theoretical minimum electrical conductivity of the alloy. In another embodiment, an aluminum alloy processed according to such methods is within 30% of the theoretical minimum electrical conductivity of the alloy. In yet another embodiment, an aluminum alloy processed according to such methods is within 20% of the theoretical minimum electrical conductivity of the alloy. In another embodiment, an aluminum alloy processed according to such methods is within 15% of the theoretical minimum electrical conductivity of the alloy, or less, Similar electrical conductivity values may be realized in the continuous casting embodiments described below in subsections (C) and (D). b. Example of continuously casting with solutionizing
  • a strip of Alloy 6-1 (0,09 inch thick) was analyzed for segregation of alloying elements, The concentration of alloying elements through the thickness of the strip is presented graphically FIG. 6e for eutectic forming elements (Si, Fe, Ni and Zn) and in FIG. 6f for peritectic forming elements (Ti, V and Zr).
  • the eutectic forming alloying elements are partially depleted in the central portion of the strip while the peritectic forming alloying elements are enriched in the central portion of the strip.
  • FIG. 6g is a photomicrograph at 25 times magnification of a transverse section through a stack of three strips of Alloy 6-1 produced at a casting speed of 188 feet per minute, mean strip thickness of 0.094 inch, strip width of 15.5 inches, and applied force of 103 pounds per inch of width.
  • the full thickness of one strip is seen in FIG. 6g between a pair of thin, dark bands.
  • the central darker band in the full strip corresponds to the central layer 18-6 described above which is partially depleted of eutectic forming alloying elements while the outer, lighter portions of the fall strip correspond to the upper and lower shells 6-6 and 8-6, described above.
  • FIG. 6h is a photomicrograph of the central strip of FIG. 6g at 100 times magnification. The globular nature of the grains in the central, darker band indicates no working of the strip occurred in the caster.
  • FIG. 6i is a photomicrograph at 25 times magnification of a transverse section through a stack of two strips of Alloy 6-2 produced at a casting speed of 231 feet per minute, roll gap of 0.0925 inch, strip width of 15.5 inches and applied force of 97 pounds per inch of width.
  • the full thickness of one strip and a portion of the other strip are illustrated by FIG. 6i.
  • the strip of FIG. 6i also exhibits a central, darker band depleted of eutectic forming alloying elements.
  • FIG. 6j is a photomicrograph of the center portion of the strip of FIG. 6i at 100 times magnification. The globular nature of the grains in the central, darker band also indicates no working of the strip occurred in the caster.
  • a strip of Alloy 6-2 (0.1 inch thick) was analyzed for segregation of alloying elements.
  • the concentration of alloying elements through the thickness of the strip is presented graphically in FIG, 6k for eutectic forming elements (Mg, Mn, Cu, Fe and Si) and in FIG. 61 for peritectic forming elements (Ti and V).
  • the eutectic forming alloying elements are partially depleted in the central portion of the strip while the peritectic forming alloying elements are enriched in the central portion of the strip.
  • 6m is a photomicrograph at 50 times magnification of a transverse section through an anodized strip of Alloy 6-3 produced at a casting speed of 196 feet per minute, mean strip thickness of about 0.098 inch, strip width of 15.6 inches, and applied force of 70 pounds per inch of width.
  • the photomicrograph shows the central portion of the strip sandwiched between upper and lower portions without showing the top and bottom surfaces of the strip.
  • the central, lighter band in the strip corresponds to the central layer 18-6 described above which is partially depleted of eutectic forming alloying elements while the outer, darker portions of the full strip correspond to the upper and lower shells 6-6 and 8-6 described above.
  • the grains shown in the strip are globular, indicating absence of working thereof.
  • FIG. 6n One support mechanism is shown FIG. 6n, and includes a continuous conveyor belt B positioned beneath the strip S exiting the rolls Ri and R 2 .
  • the belt B travels around pulleys P and supports the strip S for a predetermined distance (e.g., about 10 feet).
  • the length of the belt B between the pulleys P may be determined by the casting process, the exit temperature of the strip S and the alloy of the strip S.
  • Suitable materials for the belt B include fiberglass and metal (e.g, steel) in solid form or as a mesh.
  • FIG. 6n One support mechanism is shown FIG. 6n, and includes a continuous conveyor belt B positioned beneath the strip S exiting the rolls Ri and R 2 .
  • the belt B travels around pulleys P and supports the strip S for a predetermined distance (e.g., about 10 feet).
  • the length of the belt B between the pulleys P may be determined by the casting process, the exit temperature of the strip S and the alloy of the strip S.
  • the support mechanism may include a stationary support surface H such as a metal shoe over which the strip S travels while it cools.
  • the shoe H may be made of a material to which the hot strip S does not readily adhere.
  • the strip S may be cooled at locations E with a fluid such as air or water.
  • the strip S exits the rolls i and R 2 at about 1100°F. It may be desirable to lower the strip temperature to about 1000°F within about 8 to 10 inches of the nip N.
  • One suitable mechanism for cooling the strip at locations E to achieve that amount of cooling is described in U.S. Pat. No. 4,823,860.
  • a separate quenching apparatus may be used to further quench the strip and achieve the above-noted cooling rates.
  • a method comprises quenching of the as-cast sheet.
  • the solutionizing step includes solution heat treating and quenching, where the solution heat treating is accomplished due to the continuous casting.
  • the preparing step further comprises removing the aluminum alloy sheet from the continuous casting apparatus, and, after the removing step, but before the aluminum alloy sheet reaches a temperature of 700°F, quenching the aluminum alloy sheet, where the quenching reduces the temperature of the aluminum alloy sheet at a rate of at least 100°F per second, thereby accomplishing the solutionizing.
  • the temperature of the aluminum alloy sheet exiting the continuous casting apparatus is higher than the temperature of the aluminum alloy sheet during the quenching step.
  • the quenching step is initiated before the aluminum alloy sheet reaches a temperature of 800°F. In another embodiment, the quenching step is initiated before the aluminum alloy sheet reaches a temperature of 900°F. In yet another embodiment, the quenching step is initiated before the aluminum alloy sheet reaches a temperature of 1000°F. In another embodiment, the quenching step is initiated before the aluminum alloy sheet reaches a temperature of 1100°F.
  • the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 200°F per second. In another embodiment, the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 400°F per second. In yet another embodiment, the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 800°F per second. In another embodiment, the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 1600°F per second. In yet another embodiment, the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 3200°F per second.
  • the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 6400°F per second. In yet another embodiment, the quenching step reduces the temperature of the aluminum alloy sheet at a rate of at least 10,000°F per second.
  • the quenching step may be accomplished to bring the aluminum alloy sheet to a low temperature (e.g., due to a subsequent cold working step).
  • the quenching comprises cooling the aluminum alloy sheet to a temperature of not greater than 200°F (i.e., the temperature of the aluminum alloy sheet upon completion of the quenching step is not greater than 200°F).
  • the quenching comprises cooling the aluminum alloy sheet to a temperature of not greater than 150°F,
  • the quenching comprises cooling the aluminum alloy sheet to a temperature of not greater than 100°F
  • the quenching comprises cooling the aluminum alloy sheet to ambient temperature.
  • the quenching step may be accomplished via any suitable cooling medium.
  • the quenching comprises contacting the aluminum alloy sheet with a gas.
  • the gas is air.
  • the quenching comprises contacting the aluminum alloy sheet with a liquid.
  • the liquid is aqueous based, such as water or another aqueous based cooling solution.
  • the liquid is an oil.
  • the oil is hydrocarbon based.
  • the oil is silicone based.
  • the quenching is accomplished via a quenching apparatus downstream of the continuous casting apparatus. In other embodiments, ambient air cooling is used.
  • the twin-roll casting apparatus and processes may generate an aluminum alloy product having particulate matter therein.
  • the particulate matter can be any non-metallic material such as aluminum oxide, boron carbide, silicon carbide and boron nitride or a metallic material created in-situ during casting or added to a molten aluminum alloy,
  • the terms "upper”, “lower”, “right”, “left”, “vertical”, “horizontal,” “top”, “bottom”, and derivatives thereof shall relate to the disclosure, as it is oriented in the drawing figures 6p through 6s, as applicable.
  • the casting / solutionizing step 142 may include continuously casting strips with particulate matter there is provided.
  • a molten aluminum alloy containing particulate matter may be delivered to a casting apparatus, such as the casting apparatus described above relative to FIGS. 6b- 1 and 6b-2.
  • the casting apparatus may rapidly cool at least a portion of the molten metal to solidify an outer region (also referred to as an area, shell, and layer) of the molten metal, and inner region (also referred to as an area, shell, and layer) enriched with particulate matter.
  • the solidified outer regions may increase in thickness as the alloy is cast.
  • the product exiting the casting apparatus may be a single-layered product and may include the solid inner regions formed in step 1026 containing the particulate matter sandwiched within the outer solid regions.
  • the single-layered product can be generated in various forms such as but not limited to a sheet, a plate, or a foil.
  • the product In extrusion casting, the product may be in the form of a wire, rod, bar or other extrusion.
  • the molten aluminum alloy metal M containing particulate matter 100-6 may be provided between rolls R[ and R 2 of the roll caster.
  • and R 2 are the casting surfaces of the roll caster.
  • Ri and R 2 are cooled to aid in the solidification of the molten metal M, which directly contacts the rolls i and R 2 at regions 2-6 and 4-6, respectively.
  • the metal M begins to cool and solidify.
  • the cooling metal solidifies as a first region or shell 6-6 of solidified metal adjacent the roll i and a second region or shell 8-6 of solidified metal adjacent to the roll R 2 .
  • each of the region or shell 8-6 and 6- 6 increases as the metal M advances towards the nip N.
  • the particulate matter 100-6 may be located at the interfaces between each of the first and second regions 8-6 and 6-6 and the molten metal M.
  • the particulate matter 100-6 may be dragged into a central region (or portion) 12-6, also referred to in this embodiment as an "inner portion," of the slower moving flow of the molten metal M and may be carried in the direction of arrows C) and C 2 .
  • the metal M is semi-solid and includes a particulate matter 100-6 component and a molten metal M component.
  • the molten metal M in the region 16-6 may have a mushy consistency due in part to the dispersion of the particulate matter 100-6 therein.
  • the forward rotation of the rolls 3 ⁇ 4 and R 2 at the nip N advances substantially only the solid portion of the metal, i.e.
  • the central region 12-6 Downstream of the nip N, the central region 12-6 is a solid central region (or layer) 18-6 containing particulate matter 100-6 sandwiched between the first region 6-6 and the region shell 8-6.
  • the single-layer, single-continuously-cast aluminum article described above having a central layer or region 18-6 with a high concentration of particulate matter 100-6 sandwiched between the first and second regions 6-6 and 8-6 shall also be referred to as a functionally graded MMC structure.
  • the size of the particulate matter 100-6 in the central layer 18-6 may be at least 30 microns.
  • the solid inner region (or portion) may constitute 20 to 30 percent of the total thickness of the strip. While, the caster of FIG. 6q is shown as producing strip 20-6 in a generally horizontal orientation, this is not meant to be limiting as the strip 20-6 may exit the caster at an angle or vertically.
  • step 1026 Molten metal delivered in step 1006 to the roll caster begins to cool and solidify in step 1026.
  • the cooling metal develops outer layers of solidified metal, i.e. first and second regions 6-6 and 8-6, near or adjacent the cooled casting surfaces Ri, R 2 .
  • the thickness of the first region (or shell) 6-6 and the second region (or shell) 8-6 increases as the metal advances through the casting apparatus.
  • the particulate matter 100-6 may be drawn into the central portion 12-6, which is partially surrounded by the solidified outer regions 6-6 and 8-6.
  • the first and second regions 6-6 and 8-6 substantially surround the central region 18-6.
  • the central region 18- 6 that contains the particulate matter 100-6 is located between the first region 6-6 and the second region 8-6, within a single-layered product along a concentration gradient. Said differently, the central region 18-6 is sandwiched between the first shell 6-6 and the second shell 8-6. In other casting apparatuses, the first and/or second shells may completely surround the inner layer.
  • the central region 18-6 may be solidified to produce an inner region (or layer). Prior to complete solidification, the central region 12-6 of the strip 20-6 is semi-solid and includes a particulate matter component and a molten metal component. The metal at this stage has a mushy consistency due in part to the dispersion of particulate matter therein,
  • the product is completely solidified and includes the inner region (or layer), which contains the particulate matter and a first and second shell, i.e. outer regions or layers, that substantially surrounds the inner region (or layer).
  • the thickness of the inner region (or layer) may be about 10-40% of the thickness of the product,
  • the inner region (or layer) may be comprised of about 70% particulate matter 100- 6 by volume, while the first and second shells are each independently comprised of about 15% particulate matter 100-6 by volume.
  • the inner region (or layer) may be comprised of at least 70% particulate matter 100-6 by volume, while the first and second shells are each independently comprised of less than 15% particulate matter 100-6 by volume.
  • movement of the particulate matter 100-6 into the inner region may be caused by the shear forces that result from the speed differences between the inner regions of molten metal and the solidified outer regions.
  • the roll casters may be operated at speeds of at least 30 fpm, alternatively at least 40 fpm, and alternatively at least 50 fpm (feet per minute).
  • particulate matter 100-6 having a size of at least 30 microns moves from being evenly distributed to a more concentrated state, i.e., into the inner region during casting.
  • roll casters operated at speeds of less than 10 feet per minute do not generate the shear forces required to move the particulate matter (which has a size of at least 30 microns) into the inner region (or layer).
  • the control, maintenance and selection of the appropriate speed of the rolls Ri and R 2 may impact the operability of the casting apparatus.
  • the roll speed determines the speed that the molten metal M advances towards the nip N. If the speed is too slow, the particulate matter 100-6 may not experience sufficient forces to become entrained in the central portion 18-6 of the metal product.
  • the apparatus is operated at speeds ranging from 50 to 300 feet per minute.
  • the linear speed that molten aluminum is delivered to the rolls R ' i and R 2 may be less than the speed of the rolls Ri and R 2 , or about one quarter of the roll speed.
  • the strip 400-6 shown comprises 15% alumina by weight and is at 0.004 inch gauge.
  • the particulate matter 410-6 can be seen distributed throughout the strip 400-6 with a higher concentration of particulates concentrated in a central region (or layer or portion) 401-06 while lower concentrations can be seen in outer regions (or layers or shells) 402-06 and 403-06 respectively. It is believed that, without wishing to be bound by the same, there is no reaction between the particulate matter 410-6 and the aluminum matrix due to the rapid solidification of the molten during casting. Moreover, there is no damage at the interface between the particulate and the metal matrix as may be seen in FIG. 6s. Because the particulate matter does not protrude above the surface of the product it does not wear or abrade the rolling mill rolls.
  • the twin-roll casting apparatus and processes may generate an aluminum alloy product having immiscible phases therein.
  • Suitable immiscible phase elements include Sn, Pb, Bi, and Cd and may be present in the amounts disclosed below in the Compositions section (Section G), below.
  • the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal,” “top”, “bottom”, and derivatives thereof shall relate to the disclosure, as it is oriented in the drawing figures 6t through 6x, as applicable.
  • the casting / solutionizing step 142 may include continuously casting strips with at least one immiscible phase therein is provided.
  • a molten aluminum alloy and at least one immiscible phase element are introduced into a suitable casting apparatus, such as the casting apparatus described above relative to FIGS. 6b-l and 6b-2,
  • the casting apparatus is operated at a casting speed ranging from 50 to 300 feet per minute.
  • the apparatus includes a pair of endless belts 1067 and 1267 that act as casting molds carried by a pair of upper pulleys 1467 and 1667 and a pair of corresponding lower pulleys 1867 and 2067.
  • Each pulley may be mounted for rotation about an axis 2167, 2267, 2467, and 2667 respectively.
  • the pulleys may be of a suitable heat resistant type, and either or both of the upper pulleys 1467 and 1667 is driven by a suitable motor means (not shown). The same is true for the lower pulleys 1867 and 2067.
  • Each of the belts 1067 and 1267 is an endless belt, and is generally formed of a metal whic has low reactivity or is non-reactive with the metal being cast. Good results have been achieved using steel and copper alloy belts, but other belts can also be used such as aluminum. It should be noted that in this embodiment of the invention casting molds are implemented as casting belts 1067 and 1267. However casting molds can comprise a single mold, one or more rolls or a set of blocks for example.
  • the pulleys are positioned, as illustrated in FIGS. 6u and 6v, one above the other with a molding gap therebetween.
  • the gap is dimensioned to correspond to the desired thickness of the metal strip being cast.
  • the thicloaess of the metal strip being cast is determined by the dimensions of the nip between belts 1067 and 1267 passing over pulleys 1467 and 1867 along a line passing through the axis of pulleys 1467 and 1867 which is perpendicular to the casting belts 1067 and 1267, Molten metal to be cast may be supplied to the molding zone through metal supply means 2867 such as a tundish.
  • tundish 2867 corresponds in width to the width of the product to be cast, and can have a width up to the width of the narrower of the casting belts 1067 and 1267.
  • the tundish 28 includes a metal supply delivery casting tip 3067 to deliver a horizontal stream of molten metal to the molding zone between the belts 1067 and 1267.
  • the tip 3067 defines, along with the belts 1067 and 1267 immediately adjacent to tip 3067, a molding zone into which the horizontal stream of molten metal flows.
  • the stream of molten metal flowing substantially horizontally from the tip fills the molding zone between the curvature of each belt 1067 and 1267 to the nip of the pulleys 1467 and 1867.
  • the casting apparatus shown in FIGS. 6u-6w may include a pair of cooling apparatus 3267 and 3467 positioned opposite that portion of the endless belt in contact with the metal being cast in the molding gap between belts 1067 and 1267.
  • the cooling means 3267 and 3467 thus serve to cool the belts 1067 and 1267 just after they pass over pulleys 1667 and 2067, respectively, and before they come into contact with the molten metal.
  • the coolers 3267 and 3467 are positioned as shown on the return run of belts 1067 and 1267, respectively.
  • the cooling apparatus 3267 and 3467 can be conventional cooling apparatus, such as fluid cooling tips positioned to spray a cooling fluid directly on the inside and/or outside of belts 1067 and 1267 to cool the belts through their thicknesses.
  • molten metal flows horizontally from the tundish through the casting tip 3067 into the casting or molding zone defined between the belts 1067 and 1267 where the belts 1067 and 1267 are heated by heat transfer from the cast strip to the belts 1067 and 1267.
  • the cast metal strip remains between and is conveyed by the casting belts 1067 and 1267 until each of them is turned past the centerline of pulleys 1667 and 2067.
  • the cooling apparatus 3267 and 3467 cool the belts 1067 and 1267, respectively, and remove therefrom substantially all of the heat transferred to the belts in the molding zone.
  • the supply of molten metal from the tundish through the casting tip 3067 is shown in greater detail in FIG. 6w, where the casting tip 3067 is formed of an upper wall 4067 and a lower wall 4267 defining a central opening 4467 therebetween whose width may extend substantially over the width of the belts 1067 and 1267.
  • the distal ends of the walls 4067 and 4267 of the casting tip 3067 are proximal the surface of the casting belts 1067 and 1267, respectively, and define with the belts 1067 and 1267 a casting cavity or molding zone 4667 into which the molten metal flows through the central opening 4467.
  • a casting cavity or molding zone 4667 into which the molten metal flows through the central opening 4467.
  • Sufficient setback (defined as the distance between first contact 4767 of the molten metal 4667 and the nip 4867 defined as the closet approach of the entry pulleys 1467 and 1867) is provided to allow substantially complete solidification prior to the nip 4867,
  • a molten aluminum alloy comprising a phase that is immiscible in the liquid state is introduced via tundish 2867, through casting tip 3067, and into the casting zone defined between belts 1067 and 1267.
  • the dimensions of the nip between belts 1067 and 1267 passing over pulleys 1467 and 1867 is in the range of 0.08 to 0.249 inches, and the casting speed is 50-300 fpm.
  • droplets of the immiscible liquid phase may nucleate ahead of the solidification front and may be engulfed by the rapidly moving freeze front into the space between the secondary dendrite arm ("SDA") spaces.
  • SDA secondary dendrite arm
  • FIG. 6x a photomicrograph of a section of a Al-6Sn (aluminum alloy having 6 percent by weight tin) strip 40067 produced in accordance with the present invention is shown.
  • the strip shows a uniform distribution of fine Sn particles 40167 which are 3 micrometers or smaller, This result is several times smaller than particles that would result from material made from an ingot or by roll casting which are typically from 40 microns to 400 microns in size.
  • the new process includes cold working (200) the aluminum alloy body a high amount.
  • Cold working and the like means deforming an aluminum alloy body in at least one direction and at temperatures below hot working temperatures (e.g., not greater than 400°F).
  • Cold working may be imparted by one or more of rolling, extruding, forging, drawing, ironing, spinning, flow-forming, and combinations thereof, among other types of cold working methods. These cold working methods may at least partially assist in producing various new HT aluminum alloy products (see, Product Applications ⁇ below). i. Cold rolling
  • the cold working step (200) comprises cold rolling (220) (and in some instances consists of cold rolling (220), with optional stretching or straightening for flatness (240)).
  • the cold rolling step (220) is completed after the solutionizing step (140).
  • Cold rolling (220) is a fabrication technique where an aluminum alloy body is decreased in thickness, generally via pressure applied by rollers, and where the aluminum alloy body enters the rolling equipment at a temperature below that used for hot rolling (124) (e.g., not greater than 400°F).
  • the aluminum alloy body enters the rolling equipment at ambient conditions, i.e., the cold rolling step (220) is initiated at ambient conditions in this embodiment.
  • the cold rolling step (220) reduces the thickness of a new HT aluminum alloy body by at least 25%.
  • the cold rolling step (220) may be completed in one or more rolling passes, In one embodiment, the cold rolling step (220) rolls the aluminum alloy body from an intermediate gauge to a final gauge.
  • the cold rolling step (220) may produce a sheet, plate, or foil product.
  • a foil product is a rolled product having a thickness of less than 0.006 inch.
  • a sheet product is a rolled product having a thickness of from 0.006 inch to 0.249 inch
  • a plate product is a rolled product having a thickness of 0.250 inch or greater.
  • Cold rolled XX% and the like means XX CR %, where XX C R% is the amount of thiclaiess reduction achieved when the aluminum alloy body is reduced from a first thickness of T
  • XXCR% is equal to:
  • XXC % 80%».
  • the aluminum alloy body is cold rolled (220) at least 30% (XXCR% > 30%), i.e., is reduced in thickness by at least 30%, In other embodiments, the aluminum alloy body is cold rolled (220) at least 35% (XX C R% > 35%), or at least 40% (XX CR % > 40%), or at least 45% (XX CR % > 45%), or at least 50% (XX CR % > 50%), or at least 55% (XX C R% > 55%), or at least 60% (XX CR % > 60%), or at least 65% (XX CR % > 65%), or at least 70% (XX C R% > 70%), or at least 75% (XX CR % > 75%), or at least 80% (XX C R% > 80%), or at least 85% (XX C R% > 85%), or at least 90% (XX C R% > 90%), or more.
  • the aluminum alloy body may be cold rolled (220) by not greater than 87% (XX C R% ⁇ 87%), such as cold rolled (220) not more than 85% (XXCR% ⁇ 85%), or not greater than 83% ( XX CR % ⁇ 83%), or not greater than 80% ( XX C R% ⁇ 80%),
  • the aluminum alloy body is cold rolled in the range of from more than 50% to not greater than 85% (50% ⁇ XX CR % ⁇ 85%). This amount of cold rolling may produce an aluminum alloy body having preferred properties.
  • the aluminum alloy body may be cold rolled in the range of from 55% to 85% (55% ⁇ XXCR% ⁇ 85%).
  • the aluminum alloy body may be cold rolled in the range of from 60% to 85% (60% ⁇ XXCR% ⁇ 85%).
  • the aluminum alloy body may be cold rolled in the range of from 65% to 85% (65% ⁇ XX C R% ⁇ 85%).
  • the aluminum alloy body may be cold rolled in the range of from 70% to
  • optional pre-cold rolling (128) may be completed.
  • This pre-cold rolling step (128) may further reduce the intermediate gauge of the aluminum alloy body (due to the hot rolling 126) to a secondary intermediate gauge before solutionizing (140).
  • the optional cold rolling step (128) may be used to produce a secondary intermediate gauge that facilitates production of a final cold rolled gauge during the cold rolling step (220). ii.
  • Other cold working techniques may be used to produce a secondary intermediate gauge that facilitates production of a final cold rolled gauge during the cold rolling step (220).
  • cold working may be imparted by one or more of extruding, forging, drawing, ironing, spinning, flow-forming, and combinations thereof, among other types of cold working methods, alone or in combination with cold rolling.
  • the aluminum alloy body is generally cold worked by at least 25% after solutionizing. In one embodiment, the cold working works the aluminum alloy body to its substantially final form (i.e., no additional hot working and/or cold working steps are required to achieve the final product form).
  • Cold working by XX% (“XX CW %") and the like means cold working the aluminum alloy body an amount sufficient to achieve an equivalent plastic strain (described below) that is at least as large as the amount of equivalent plastic strain that would have been achieved if the aluminum alloy body had been cold rolled XX% (XX C R%).
  • cold working 68.2% means cold working the aluminum alloy body an amount sufficient to achieve an equivalent plastic strain that is at least as large as the amount of equivalent plastic strain that would have been achieved if the aluminum alloy body had been cold rolled 68.2%.
  • XXcw% and XXCR% both refer to the amount of equivalent plastic strain induced in an aluminum alloy body as if the aluminum alloy body was cold rolled XX% (or actually is cold rolled XX% in the case of actual cold rolling), those terms are used interchangeably herein to refer to this amount of equivalent plastic strain.
  • Equivalent plastic strain is related to true strain.
  • cold rolling XX% i.e., XXCR%
  • true strain values where true strain (8 tme ) is given by the formula:
  • true strain values may be converted to equivalent plastic strain values.
  • the estimated equivalent plastic strain will be 1,155 times greater than the true strain value (2 divided by the 3 equals 1.155).
  • Biaxial strain is representative of the type of plastic strain imparted during cold rolling operations.
  • the cold working step (200) may include deforming the aluminum alloy body in a first manner (e.g., compressing) and then deforming the aluminum alloy body in a second manner (e.g., stretching), and that the equivalent plastic strain described herein refers to the accumulated strain due to all deformation operations completed as a part of the cold working step (200). Furthermore, those skilled in the art appreciate that the cold working step (200) will result in inducement of strain, but not necessarily a change in the final dimensions of the aluminum alloy body.
  • a first manner e.g., compressing
  • a second manner e.g., stretching
  • an aluminum alloy body may be cold deformed in a first manner (e.g., compressing) after which it is cold deformed in a second manner (e.g., stretching), the accumulated, results of which provide an aluminum alloy body having about the same final dimensions as the aluminum alloy body before the cold working step (200), but with an increased strain due to the various cold deformation operations of the cold working step (200).
  • high accumulated strains can be achieved through sequential bending and reverse bending operations.
  • the accumulated equivalent plastic strain, and thus XX C % ⁇ may be determined for any given cold working operation, or series of cold working operations, by computing the equivalent plastic strain imparted by those cold working operations and then determining its corresponding XXCR% value, via the methodologies shown above, and other methodologies known to those skilled in the art.
  • XXcw% cold working by XX%
  • XXcw% cold working by XX%
  • the cold working (200) is accomplished such that the aluminum alloy body realizes an XX C w% or C % ⁇ 25%, i.e., > 0.3322 equivalent plastic strain.
  • the amount of equivalent plastic strain, and thus the amount of XXcw or XXCR is determined on the portion(s) of the aluminum alloy body receiving the cold work (200),
  • the aluminum alloy body is cold worked (200) sufficiently to achieve, and realizes, an equivalent plastic strain ("EPS") of at least 0.41 19 (i.e., XX C w% ⁇ 30%).
  • EPS equivalent plastic strain
  • the aluminum alloy body is cold worked (200) sufficiently to achieve, and realizes, an EPS of at least 0.4974 (XX CW % > 35%), or at least 0.5899 (XX C w% > 40%), or at least 0.6903 (XX C w% > 45%), or at least 0.8004, (XX CW % ⁇ 50%), or at least 0.9220 (XXcw% > 55%), or at least 1.0583 (XX CW % > 60%), or at least 1.2120 (XX CW % ⁇ 65%), or at least 1,3902 (XX C w% > 70%), or at least 1.6008 (XX C % > 75%), or at least 1.8584 (XX CW % > 80%), or at least 2.1906 (XXX CW
  • the aluminum alloy body may be cold worked (200) not more than 87% (XX C w% ⁇ 87% and EPS ⁇ 2.3564), such as cold worked (200) not more than 85% (XX C w% ⁇ 85% and ' EPS ⁇ 2.1906), or not more than 83% (XX CW % ⁇ 83% and EPS ⁇ 2.0466), or not more than 80% (XX C w% ⁇ 80% and EPS ⁇ 1.8584).
  • the aluminum alloy body is cold worked (200) in the range of from more than 50% to not greater than 85% (50% ⁇ XX C w% ⁇ 85%). This amount of cold working (200) may produce an aluminum alloy body having preferred properties.
  • the aluminum alloy body is cold worked (200) in the range of from 55% to 85% (55% ⁇ XXcw% ⁇ 85%o).
  • the aluminum alloy body is cold worked (200) in the range of from 60% to 85% (60% ⁇ XX CW % ⁇ 85%).
  • the aluminum alloy body is cold worked (200) in the range of from 65% to 85% (65% ⁇ XXcw% ⁇ 85%o).
  • the aluminum alloy body is cold worked (200) in the range of from 70% to 80% (70% ⁇ XX CW % ⁇ 80%).
  • the cold working step (200) may be tailored to deform the aluminum alloy body in a generally uniform manner, such as via rolling, described above, or conventional extruding processes, among others.
  • the cold working step may be tailored to deform the aluminum alloy body in a generally non-uniform . manner.
  • the process may produce an aluminum alloy body having tailored cold working gradients, i.e., a first portion of the aluminum alloy body receives a first tailored amount of cold work and a second portion of the aluminum alloy body receives a second tailored amount of cold work, where the first tailored amount is different than the second tailored amount.
  • cold working operations (200) that may be completed, alone or in combination, to achieve tailored non-uniform cold work include forging, burnishing, shot peening, flow forming, and spin-forming, among others. Such cold working operations may also be utilized in combination with generally uniform cold working operations, such as cold rolling and/or extruding, among others.
  • the amount of equivalent plastic strain is determined on the portion(s) of the aluminum alloy body receiving the cold work (200).
  • such products may have a first portion having a first strength and a second portion having a second strength, with the first strength being different than the second strength.
  • Tailored products may be useful, for example, in situations where higher strength is required in one part of a material, but lower strength and/or higher ductility may be required in another part of a material.
  • an automotive component or aerospace component may have forming requirements, such as tight bend radii and/or deep draw requirements around its perimeter, but may also require high strength were it is attached to other components (e.g., via bolting, riveting or welding).
  • these two characteristics oppose each other,
  • a single panel could meet both requirements,
  • tailored cold working may be used to produce a monolithic aluminum alloy body (e.g., a sheet, plate, or tubulars) having a first portion and a second portion, wherein the first portion has at least ' 25% cold work, and wherein second portion has at least 5% less cold work than the first portion, i.e., the first and second portions have different amounts of induced cold work (e.g., see FIGS, 2b-2m, described below).
  • "at least XX% less cold work” and the like means that the XX% value is subtracted from the first cold work percent value. For example, when a second portion has at least XX% less cold work than a first portion having at least YY% cold work, the second portion would have a cold work of ⁇ YY% - XX%.
  • the second portion is adjacent the first portion (e.g., see FIG. 2j, below).
  • adjacent means near or close to, but not necessarily touching.
  • an adjacent second portion touches the first portion.
  • the second portion is not adjacent and is remote of the first portion, such as when the first portion is a first end of the monolithic aluminum alloy body and the second portion is a second end of the monolithic aluminum alloy body (e.g., see FIGS. 2b and 2d, described below),
  • the monolithic aluminum alloy body having the first and second portions is a sheet or plate.
  • this sheet or plate has a uniform thickness (e.g., see FIGS. 2d,. 2e, 2g, 2h, 2j, and 2k, described below).
  • the sheet or plate has a non-uniform thickness, where the first portion is associated with a first thickness of the sheet or plate, and the second portion is associated with a second thickness of the sheet or plate (e.g., see FIGS. 2i and 21, described below).
  • the first portion of the monolithic aluminum alloy body has at least 30% cold work. In other embodiments, the first portion has at least 35% cold work, such as at least 40% cold work, or at least 45% cold work, or at least 50% cold work, or at least 55% cold work, or at least 60% cold work, or at least 65% cold work, or at least 70% cold work, or at least 75% cold work, or at least 80% cold work, or at least 85%» cold work, or at least 90% cold work, or more.
  • the second portion may have at least 10% less cold work than the first portion. In one of these embodiments, the second portion may have at least 15%» less cold work than the first portion.
  • the second may have at least 20% less cold work than the second portion, or at least 25% less cold work, or at least 30% less cold work, or at least 35% less cold work, or at least 40% less cold work, or at least 45% less cold work, or at least 50% less cold work, or at least 55% less cold work, or at least 60% less cold work, or at least 65%» less cold work, or at least 70% less cold work, or at least 75% less cold work, or at least 80% less cold work, or at least 85%» less cold work, or at least 90% less cold work, than the first portion.
  • the second portion receives no cold work during the cold working operation.
  • the first portion of the monolithic aluminum alloy body has at least 5% higher strength (tensile yield strength and/or ultimate tensile strength) as compared to the second portion, In other embodiments the first portion of the monolithic aluminum alloy body has at least 10%» higher, or at least 20%» higher, or at least 30%» higher, or at least 40%» higher, at least 50% higher, or at least 60%» higher, or at least 70%» higher, or at least 80% higher, at least 90% higher, or at least 100%» higher (2x) or more as compared to the second portion. In one embodiment, the first portion has ah elongation of at least 4%».
  • the first portion has an elongation of at least 6%», or at least 8%, or at least 10%, or at least 12%, or higher.
  • the second portion has higher elongation than the first portion (relates to ductility / formability),
  • These monolithic aluminum alloy bodies having the first portion and the second portion may be formed into a component of an assembly.
  • a coiiiponent may be formed into a predetermined shaped product (defined in Section F, below).
  • a component having the first portion is a component of an assembly, and the first portion is associated with an attachment point of that assembly, such as an attachment point of a mobile apparatus (e.g., of a vehicle) or a stationary apparatus (e.g., a building).
  • the component is a component of a vehicle.
  • the component comprises the first portion and the second portion of the monolithic aluminum alloy body, and the first portion has a higher strength than the second portion.
  • the vehicle is an automotive vehicle, and an attachment point relates to a "point- load position" of the vehicle.
  • a "point load position” is a position characterized by a point load condition, and may relate to a mobile body or a stationary body.
  • a "point-load condition” is a condition in a structure (mobile or stationary) characterized by a high load transfer, concentrated at a location. This load transfer may occur at the attachment location(s) of the structure, such as in an area typically joined by welding, riveting, bolting, and the like.
  • a point load position may be potentially subjected to high stresses (e.g., a crash event for a ground-based vehicle; wing attachment locations for aerospace vehicles).
  • the following automotive components may be related to a point-load position of an automotive vehicle: seat rail attachment points (front and rear), seat belt attachment points, accessory attachment points (e.g., firewalls), door guard beam attachment points (e.g., hinges, anchor points, locking mechanisms / latches, door guard beam attachment points), engine mounts, body mounts, shock towers and suspension control arms, among others. Many of these components are illustrated in FIGS. 2n-2o and 2p-l to 2p ⁇ 3.
  • the vehicle may be another ground-based vehicle, such as a bus, van, truck tractor, box trailer, flatbed trailer, recreational vehicles (RVs), motorcycles, all-terrain vehicles (ATVs), and the like, and a component may be tailored for these vehicles such that the first portion is associated with an attachment point.
  • the vehicle may be an aerospace vehicle, the component is an aerospace component, and the first portion of the component may be associated with an attachment point of the aerospace vehicle, for example.
  • the vehicle may be a marine vessel, the component is a marine component, and the first portion of the component may be associated with an attachment point of the marine vehicle.
  • the vehicle may be a rail car or locomotive
  • the component is a rail car or locomotive component
  • the first portion of the component may be associated with an attachment point of the rail car or locomotive.
  • These components may be used in other non-vehicle assemblies, such as armor components in a ballistics assembly or a component for an offshore platform, for example.
  • the monolithic aluminum alloy body having the first portion and the second portion may be processed to achieve a predetermined condition, such as any of the predetermined conditions described in the Thermal Treatment section (Section C(i)), described below,
  • a predetermined condition such as any of the predetermined conditions described in the Thermal Treatment section (Section C(i)), described below
  • at least one of the first portion and the second portion achieve the predetermined condition (322) so as to facilitate production of monolithic aluminum alloy, bodies having tailored properties.
  • the first portion may be processed to achieve a first predetermined condition (e.g., a first predetermined strength and/or elongation)
  • the .second portion may be processed to achieve a second predetermined condition (e.g., a second predetermined strength and/or elongation), wherein the second predetermined condition is different than the first predetermined condition.
  • the first portion is processed to a first predetermined strength (e.g., a predetermined tensile yield strength. and/or a predetermined ultimate tensile strength), and the second portion is processed to a second predetermined strength, where the first predetermined strength is higher than the second predetermined strength.
  • the first predetermined strength is at least 5% higher than the second predetermined, such as any of strength differentials between the first and second portions described above.
  • the second portion may realize a higher elongation than the first portion.
  • Such aluminum alloy bodies may be useful, for example, to provide tailored energy absorption properties, potentially in combination with tailored reinforcement properties.
  • a component made from a monolithic aluminum alloy body having the first portion and the second portion may be designed and produced such that the second portion is associated with an energy absorption zone (e.g., with higher ductility, optionally with lower strength) and the first portion is associated with a reinforcement zone (e.g., with higher strength, optionally with lower ductility).
  • energy absorption zone e.g., with higher ductility, optionally with lower strength
  • reinforcement zone e.g., with higher strength, optionally with lower ductility
  • Such components may be useful, for example, in automotive and armor applications, among others.
  • such a component is an automotive component designed for lightweight crash management.
  • automotive components include: front crash cans, pillars (e.g., A-pillars, B-pillars), rocker or sill panels, front upper rails (shotgun), lower longitudinals, windshield headers, upper roof siderails, seat rails, door guard beams, rear longitudinals, and door panels, among others. Many of these components are illustrated in FIGS. 2n-2o and 2p ⁇ l to 2p-3,
  • the second portion may be adjacent the first portion. In other embodiments, the second portion is remote of the first portion. In some of the latter embodiments, the first portion is a first end of the monolithic aluminum alloy body and the second portion is a second end of the monolithic aluminum alloy body, wherein the first end comprises at least 25% cold work, and wherein second end has at least 5% less cold work as compared to the first end. In another embodiment, such bodies may be of non-uniform thickness, where the first end has a first thickness, the second end has a second thickness, and the first thickness is at least 10% thinner than the second thickness.
  • Such bodies may alternatively have a uniform thickness where the first end has a first thickness, the second end has a second thickness, and where the first thickness is within 3% of the second thickness (e.g., within 1% of the second thickness, or within 0.5% of the second thickness, or within 0.1% of the second thickness, or less),
  • the aluminum alloy body may have a middle portion separating the first end and the second end.
  • the amount of cold work in the middle portion tapers from the first end to the second end, or vice versa (e.g., see FIGS. 2b, 2d and 2i, described below).
  • the middle portion generally uniformly tapers from the first end to the second end (e.g., see FIGS. 2b and 2d).
  • the amount of cold work non-uniformly changes from the first end to the second (e.g., see FIGS 2c, 2e and 2f, described below).
  • the first end and the second ends are associated with the longitudinal direction of the monolithic aluminum alloy body, and thus properties may be tailored relative to in the "L" direction of the product, In another embodiment, the first end and the second ends are associated with the transverse direction of the sheet or plate, and thus properties may be tailored relative to in the "LT" or transverse direction of the product.
  • the first and/or second portions may achieve improved properties, such as any of the properties listed in the properties listed in the Properties section (Section H), below.
  • both the first and second portions achieve an improvement in strength as compared to one or more of (a) the aluminum alloy body in the as-cold worked condition and (b) a reference version of aluminum alloy body in one the T6 temper, such as any of the improved strength properties / values listed in the Properties section (Section H), below.
  • the terms "as- cold worked condition", and "a referenced aluminum alloy body in the T6 temper” are defined in Section D, below.
  • both the first and second portions achieve an improvement in strength and elongation as compared to one or more of (a) the aluminum alloy body in the as-cold worked condition and (b) a reference version of aluminum alloy body in one the T6 temper, such as any of the improved strength properties / values listed in the Properties section (Section H), below,
  • FIGS. 2b-21 Some embodiments of aluminum alloy bodies, apparatus and methods for producing tailored amounts of cold work within an aluminum alloy bodies having a tailored amount of cold work are illustrated in FIGS. 2b-21, In one approach, a monolithic aluminum alloy body having non-uniform profiles prior to the cold working step (200) is used. Examples of aluminum alloy bodies having a non-uniform profile are illustrated in FIGS. 2b and 2c.
  • the aluminum alloy body 210b is in the form of a trapezoidal solid (wedge-shaped), having a first height HI associated with a first end 21 Ob-El and a second height H2 associated with a second end 210b-E2, the second height H2 being different than the first height H , in this case being shorter than the first height.
  • An aluminum alloy body having such a profile may be produced via extruding (or other forming processes), or by machining the aluminum alloy body prior to, or concomitant to, the solutionizing step (140).
  • the aluminum alloy body 210b exits the cold working apparatus 210r at a single gauge (e.g., final gauge), but, due to the height differential, the second end 210b-E2 will receive less cold work than the first end 210-E1, and the amount of cold work will vary across the aluminum alloy body 210b between these two ends 21 Ob-El and 210b-E2 due to the slope of the trapezoidal solid.
  • the amount of cold work induced at first end 21 Ob-El is at least 25%, and may be any of the cold work levels described above in Sections (B)(i) or (B)(ii).
  • aluminum alloy body 210b may have a first level of cold work associated with first end 21 Ob-El and a second level of cold work associated with second end 210b-E2, and with the amount of cold work generally uniformly decreasing ' between first end 21 Ob-El and second end 210b-E2. That is, the amount of cold work induced in the aluminum alloy body in the rolling direction (L direction) will generally uniformly decreasing between first end 21 Ob-El and second end 210b-E2. However, the amount of cold work in the long transverse (LT) direction will generally be the same for any given LT plane.
  • a wing skin may have an inboard end (adjacent the fuselage) and an outboard end, with the outboard end receiving more cold work (i.e., associated with the first end), and thus having higher strength (possibly with higher stiffness), and with the inboard end receiving less cold work (i.e., associated with the second end) and thus having improved damage tolerance (toughness and/or fatigue crack growth resistance).
  • an aluminum alloy body that is to be rolled comprises at least one curved surface, which may be concave or convex, depending on application. When multiple curved surfaces are used, multiple different curves will be present, each of which may be concave or convex, depending on application.
  • aluminum alloy body 210b could be rotated about 90° such that first end 21 Ob-El and second end 210b-E2 enter the rollers 21 Or at about the same time,
  • the amount of cold work induced at first end 21 Ob-El is at least 25%, and may be any of the cold work levels described above in Sections (B)(i) or (B)(ii).
  • the amount of cold work induced in the aluminum alloy body in the transverse direction will generally uniformly decrease between first end 21 Ob-El and second end 210b-E2.
  • the amount of cold work in the L direction will generally be the same for any given L direction plane.
  • first spar cap having a first property (e.g., higher strength) and a second spar cap having a second property (e.g., lower strength, higher damage tolerance (toughness and/or fatigue crack growth resistance)
  • first property e.g., higher strength
  • second property e.g., lower strength, higher damage tolerance (toughness and/or fatigue crack growth resistance)
  • an aluminum alloy body 210c may have a plurality of different profiles 210pl - 210p9 prior to the cold working step (200) so as to induce variable cold work across the aluminum alloy body after the cold working step (200).
  • aluminum alloy body 210c includes a plurality of generally flat profiles 21 Op 1 , 210p3 5 210p5, 210p7, and 210p9 and a plurality of stepped, tapered profiles 210p2, 210p4, 210p6, 210p8 separating the plurality of flat profiles, Such profiles may be produced by, for example, extruding or machining an aluminum alloy body prior to the solutionizing step (140).
  • rolled aluminum alloy body 210d receives a first amount of cold work in sections 210CW1 and 210CW9, a second amount of cold work in sections 210CW2 and 210CW8, a third amount of cold work in sections 2 IOC W3 and 210CVV7, a fourth amount of cold work in sections 210CW4 and 210CW6, and a fifth amount of cold work in section 210CW5, with the fifth amount of cold work being higher than the fourth amount of cold work, which is higher than the third amount of cold work, which is higher than the second amount of cold work, which is higher than the first amount of cold work, At least
  • At least two of the sections receive at least 25% cold work. In another embodiment, at least three of these sections receive at least 25% cold work. In yet another embodiment, at least four of these sections receive at least 25% cold work. In another embodiment, all sections receive at least 25% cold work. In one embodiment, at least one of the sections receives no cold work (e.g., is at final gauge before cold working). While FIG. 2e illustrates several different sections, the principles of FIG, 2e may be applied to any aluminum alloy body having at least two different sections, each section having a different height so as to a cold work differential upon rolling.
  • the difference in cold work between one section of the aluminum alloy body and at least one other section of the aluminum alloy body is at least 10%, i.e., a first section has at least 10% more or less cold work, as the case may be, than at least one other section. In another embodiment, a first section has at least 15% more or less cold work, as the case may be, than at least one other section. In yet another embodiment, a first section has at least 20% more or less cold work, as the case may be, than at least one other section. In another embodiment, a first section has at least 25% more or less cold work, as the case may be, than at least one other section.
  • a first section has at least 30% more or less cold work, as the case may be, than at least one other section. In another embodiment, a first section has at least 35% more or less cold work, as the case may be, than at least one other section, In yet another embodiment, a first section has at least 40% more or less cold work, as the case may be, than at least one other section, In another embodiment, a first section has at least 45% more or less cold work, as the case may be, than at least one other section, In yet another embodiment, a first section has at least 50% more or less cold work, as the case may be, than at least one other section. In another embodiment, a first section has at least 55% more or less cold work, as the case may be, than at least one other section.
  • a first section has at least 60%» more or less cold work, as the case may be, than at least one other section. In another embodiment, a first section has at least 65% more or less cold work, as the case may be, than at least one other section. In yet another embodiment, a first section has at least 70% more or less cold work, as the case may be, than at least one other section. In another embodiment, a first section has at least 75% more or less cold work, as the case may be, than at least one other section. In yet another embodiment, a first section has at least 80% more or less cold work, as the case may be, than at least one other section.
  • a first section has at least 85% more or less cold work, as the case may be, than at least one other section. In yet another embodiment, a first section has at least 90% more or less cold work, as the case may be, than at least one other section.
  • the above-described tailored cold working differentials apply to any of the tailored cold working embodiments illustrated in FIGS. 2b-2m, and also to any other embodiments where tailored cold working may be induced, [0097] In the embodiment illustrated in FIG, 2d, the amount of cold work induced in the aluminum alloy body in the rolling direction (L direction) will vary according to the profiles 21 Op 1 -210p9 and corresponding cold work sections 210CW1 - 210CW9.
  • LT long transverse
  • Such products may be useful as, for example, a component or part that requires high formability on one end, but high strength on the other, such as stiffeners for aerospace components, buses, trucks, railcars, pressure vessels, and marine components, among others.
  • aluminum alloy body 210c could be rotated about 90° such that first end 210c-El and second end 210c-E2 enter the rollers 21 Or at about the same time.
  • the amount of cold work induced in the aluminum alloy body in the LT direction will vary according to the profiles 210pl-210p9 and corresponding cold work sections 210CW1 - 210CW9, However, the amount of cold work in the L direction will generally be the same for any given L direction plane.
  • This embodiment might be useful, for example, as a rocker panel of a door for a car, where high formability is required at the ends, but high strength in desired the center, among others, and as an automotive illar (A-pillar, B-pillar, C-pillar), or other body-in-white components.
  • an aluminum alloy body 210g having variable profiles may be cold worked into a generally uniform gauge final product 210gfp, such as into a cylindrical shape, as illustrated.
  • the cold working may be accomplished by, for example, cold forging steps 210g-l and 210g-2. Fewer or more cold forging steps may be employed.
  • the final product 210gfp may have variable sections of cold work due to the variable profile of the aluminum alloy body prior to the cold working.
  • the final product 210gfp would generally contain a first amount of cold work in the middle portion (MP) of the cylinder, a second portion of cold work near the edges (E) of the cylinder, and a generally uniformly decreasing amount of cold work extending from the middle portion (MP) to the edges (E), with at least the middle portion (MP) receiving at least 25% cold work, such as any of the cold work levels described above in Sections (B)(i) or (B)(ii).
  • an aluminum alloy body 21 Oh having variable profiles may be cold worked into a generally uniform gauge final product 210hfp, such as i to a cylindrical shape, as illustrated.
  • the cold working may be accomplished by, for example, cold forging steps 210h ⁇ 1 and 210h-2, Fewer or more cold forging steps may be employed.
  • the final product 210hfp may have variable sections of cold work due to the variable profile of the aluminum alloy body prior to the cold working.
  • the final product 210hfp would generally contain a first amount of cold work in the middle portion (MP) of the cylinder, a second portion of cold work near the edges (E) of the cylinder, and a generally uniformly increasing amount of cold work extending from the middle portion (MP) to the edges (E), with at least the edges (E) receiving at least 25% cold work, such as any of the. cold work levels described above in Sections (B)(i) or (B)(ii),
  • a cold working apparatus is varied to induce variable cold work in an aluminum alloy body.
  • an intermediate gauge product 21 Oi may be rolled via rollers 21 Or, wherein, during the rolling, the rollers are gradually separated so as to produce trapezoidal solid (wedge piece) 210ts having variable cold work in the L direction.
  • Aluminum alloy body 210ts will have variable cold work from a first end to a second end, and, in this case, such variable cold work will generally uniformly taper from a first end to a second end, with at least one of the ends receiving at least 25% cold work, such as any of the cold work levels described above in Sections (B)(i) or (B)(ii).
  • Rollers 21 Or may also be non-uniformly varied to produce any appropriate profiled end product,
  • an apparatus may produce a predetermined pattern in the aluminum alloy body prior to the solutionizing step (140).
  • an aluminum alloy body 211 may be fed to one or more forming / embossing rolls 212, which may roll the aluminum alloy body 211 to a first gauge (e.g., an intermediate gauge) and may also produce a plurality of raised portions 214 via its indented portions 213.
  • a first gauge e.g., an intermediate gauge
  • the aluminum alloy body may be solutionized 140, after which it may be cold rolled to a second gauge via cold roller 21 Or.
  • the second gauge may be a final gauge, and may be the same or different than the first gauge.
  • the cold rolled aluminum alloy body 21 lcr may thus include a plurality of segregated first portions 215 having a first amount of cold work, and a plurality of second portions 216 having a second amount of cold work, with at least some of the first portions 215 receiving at least 25% cold work, such as any of the cold work levels described above in Sections ' (B)(i) or (B)(ii).
  • monolithic aluminum alloy bodies having tailored three-dimensional cold working amounts may be produced, and with the first portions being deterministically placed in one or more of the longitudinal direction and the long transverse direction of the rolled product (i.e., anywhere in the X-Y coordinate plane, where X relates to the longitudinal direction and Y relates to the transverse direction).
  • each rolling apparatus may include multiple roll stands and/or may use multiple passes to accomplish the rolling,
  • the first portions 215 receive a higher amount of cold work than the second portions 216, and the second portions 216 generally surround the first portions 215. In one embodiment, at least some of the first portions receive at least 5% more cold work than the second portions (such as any of the cold work differences described above). In one embodiment, the second portions receive at least some cold work. In one embodiment, the second portions also receive at least 25% cold work. In another embodiment, the second portions receive little or no cold work (i.e., the first gauge is generally equivalent to the second gauge).
  • gripping portions 21 may be utilized on the aluminum alloy body so that the body can be forced though one or more rollers, e.g., utilized at the edges of aluminum alloy body, as illustrated in FIG. 2j. While such gripping portions 219 are illustrated as being on the edges of the aluminum alloy body, they may also or alternatively be located in one or more middle portions of the body, if appropriate, to facilitate movement of the body through the rolling apparatus.
  • the first portions 215 may each receive generally the same amount of cold work, such as when indents 213 of roll 212 are of generally the same size so as to produce raised portions 214 of generally the same size.
  • at least one of the first portions receives a first amount of cold work and at least another of the first portions receives a second amount of cold work, such as when indents 213 of roll 212 have at least two different sizes, and thus produce raised portions 214 of different sizes.
  • at least some of the first portions receive at least 25% cold work, while others of the first portions may receive less then 25% cold work.
  • the first portions 215 may include one or more identifiers.
  • the visual identifiers 217a may be imparted by embossing roll 212, and carried over through the cold rolling operation. Such identifier(s) 217a may be used to identify where the patterns of first portions 215 are located, so that the material can be separated appropriately.
  • the first portions 215 may be visually identified by embossed markings on the first portions themselves. These indicators 217a can be used, for example, to identify high strength areas, and/or so that the recipient of the material can verify that such areas were, in fact, produced in the material.
  • a visual identifier 217b may be used to identify where to separate the material after the cold working step, such as registration marks and the like (e.g., to set the start/finish of a material blank).
  • the monolithic bodies produced as shown in FIG. 2j may be useful, for example, in producing an aerospace component having tailored high strength portions.
  • such monolithic bodies may be useful as a wing skin or a fuselage panel.
  • the high strength portions e.g., first portions
  • the high strength portions may be used relative to attachment points, or may be located where the stringers, ribs or frames attach to the wing skin or fuselage panel, as appropriate.
  • a plurality of recessed portions 218 may be imparted into the aluminum alloy body, with these recessed portions 218 being adjacent to one or more raised portions 214 prior to the cold rolling 21 Or.
  • Such recessed portions 218 may accommodate the material of the raised portions 214 during the cold working process.
  • the recessed portions 218 may be imparted, for example, by using an appropriate rolling wheel (e.g., one having at least one raised surface so as to produce a channel / recessed portion), or by machining, for example.
  • the recessed portions 218 may be appropriately shaped for the cold working process.
  • recessed portions 218 when a vertical press die is used to cold work the material, generally symmetrical recessed portions 218 may be used, with such recessed portions generally surrounding the raised portions 214.
  • non-symmetrical recessed portions 218 may be used to accommodate flow of the raised portions 214, such as by having recessed portions 218 located adjacent to the back and/or lateral sides of each of the raised portions 218, among other configurations.
  • Such recessed portions 218 can be appropriately sized and/or shaped to facilitate an appropriate level of residual stress.
  • the roller 212 may include an indentation 213 that produces an aluminum alloy body having an extended raised portion 214.
  • the raised portion 214 extends the length of the body until it reaches the cold rollers 21 Or.
  • recessed portions 218 may be located adjacent one side (or both sides) of the extended raised portion 214.
  • This body may be solutionized and, after solutionizing 140, the cold rolling 21 Or will flatten and work the raised portion 214, and may produce an aluminum alloy body having a generally uniform gauge (e.g., a final gauge), but with a first cold worked portion 215 extending the length of the body.
  • One or more second portions 216 may extend adjacent the high cold work portion 215, which second portions may or may not receive cold work.
  • the first portion 215 extends the length of the aluminum alloy body in the L direction, and is surrounded by, and is adjacent to, two second portions 216 that also extend the length of the aluminum alloy body in the L direction.
  • Such aluminum alloy bodies may be useful, for example, as automotive rocker panels.
  • FIG. 2k may be reversed (not illustrated), where roller 212 includes two indentations 213 on either edge of roller 212, thus producing first portions 215 located on the edges of the rolled product.
  • a second portion 216 separates the first portions 215, and is located in the middle portion of the rolled product.
  • the first and second portions may be of generally similar thickness, but with the edges 215 having high cold work and with the middle 216 having lower or no cold work.
  • Such aluminum alloy bodies may be useful for example, as a component where attachments are made on the edges of the product, and the middle of the product may require, for example, higher ductility. While not shown in FIG. 2k, the aluminum alloy body may include as many generally parallel first portions 215 and second portions 214, as appropriate for any particular application.
  • a generally uniform rolled product of intermediate gauge is supplied to cold roller 21 Or.
  • the cold roller 21 Or includes indentation 213, which produces second portion 216 that extends the length of the body after it exits the cold roller 21 Or.
  • the cold roller 21 Or also produces first portions 215, with at least one of the first portions having at least 25% cold work.
  • the second portion 216 may or may not receive cold work.
  • the two first portions 215 extend the length of the aluminum alloy body in the L direction, and are separated by a second portion 216 that also extends the length of the aluminum alloy body in the L direction, but has a different (larger) thickness than first portions 215.
  • Such aluminum alloy bodies may be useful in, for example, in product applications where extra thickness is required to provide stiffness (e.g., aerospace wing skins, rail cars).
  • a cold roller may be of varying diameter relative to the LT direction, thus producing a plurality of portions, each of the portions having a different amount of cold work, but with at least one of the portions receiving at least 25% cold work.
  • the aluminum alloy body may include as many generally parallel first portions 215 and second portions 214, as appropriate for any particular application.
  • a cold working apparatus may include a device that selectively removes only a portion of an aluminum alloy body (e.g., via machining), which may also produce materials similar to those illustrated in FIG, 21,
  • the device perforates a portion of the aluminum alloy body, e.g., to facilitate removal of stresses so that the aluminum alloy body does not twist, warp or otherwise distort.
  • the device removes a portion of the thickness of the aluminum alloy body.
  • the device separates the produced materials so that the aluminum alloy body does not twist, warp or otherwise distort,
  • variable amounts of cold work can be imparted along the length of tubular products by one or more of swaging, flow forming, shear forming, cold forging, or cold expansion, to name a few.
  • variable levels of cold work can be imparted after the solutionizing step and before the thermal treating step or can by imparted prior to the solutionizing step, in which case machining may also be used to create the initial geometry.
  • the cold working step can provide an aluminum alloy product that is either uniform in final cross section or having variable final geometry. Such methods might be useful, for example, in creating pipes or tubes with different properties in one or both ends compared to the central sections.
  • a monolithic aluminum alloy tubular product having a first portion and a second portion adjacent the first portion, wherein the first portion comprises at least 25% cold work, and wherein second portion has at least 5% less cold work as compared to the first portion, such as any of the above-described cold work differentials.
  • the monolithic aluminum alloy tubular product has a uniform inner diameter. In one embodiment, the monolithic aluminum alloy tubular product has a uniform outer diameter. In one embodiment, the monolithic aluminum alloy tubular product has a uniform inner and outer diameter.
  • FIGS. 2b-2m While the features of FIGS. 2b-2m have generally been described relative to cold rolling and/or cold forging, other cold working mechanisms may also be employed to produce aluminum alloy bodies having tailored cold work.
  • aluminum alloy bodies having variable profiles can be produced in a variety of known manners, including those described above, and also via extruding, forging, and machining, among others, Such profiled aluminum alloy bodies can then be cold worked in any of the above described manners to produce aluminum alloy bodies having tailored cold work,
  • the cold working step (200) may be initiated at temperatures below hot working temperatures (e.g., not greater than 400°F), In one approach, the cold working step (200) is initiated when the aluminum alloy body reaches a sufficiently low temperature after solutionizing (140). In one embodiment, the cold working step (200) may be initiated when the temperature of the aluminum alloy body is not greater than 250°F. In other embodiments, the cold working step (200) may be initiated when the temperature of the aluminum alloy body is not greater than 200°F, or not greater than 175°F, or not greater than 150°F, or not greater than 125 , or less. In one embodiment, a cold working step (200) may be initiated when the temperature of the aluminum alloy body is around ambient. In other embodiments, a cold working step (200) may be initiated at higher temperatures, such as when the temperature of the aluminum alloy body is in the range of from 250°F to less than hot working temperatures (e.g., less than 400°F).
  • the cold working step (200) is initiated and/or completed in the absence of any purposeful / meaningful heating (e.g., purposeful heating that produces a material change in the microstructure and/or properties of the aluminum alloy body).
  • purposeful heating e.g., purposeful heating that produces a material change in the microstructure and/or properties of the aluminum alloy body.
  • an aluminum alloy body may realize an increase in temperature due to the cold working step (200), but that such cold working steps (200) are still considered cold working (200) because the working operation began at temperatures below those considered to be hot working temperatures.
  • each one of these operations may employ any of the above- described temperature(s), which may be the same as or different from the temperatures employed by a prior or later cold working operation.
  • the cold working (200) is generally initiated when the aluminum alloy body reaches a sufficiently low temperature after solutionizing (140).
  • no purposeful / meaningful thermal treatments are applied to the aluminum alloy body between the end of the solutionizing step (140) and the beginning of the cold working step (200), i.e., the process may be absent of thermal treatments between the completion of the solutionizing step (140) and the initiation of the cold working step (200).
  • the cold working step (200) is initiated soon after the end of the solutionizing step (140) (e.g., to facilitate cold working).
  • the cold working step (200) is initiated not more than 72 hours after the completion of the solutionizing step (140), In other embodiments, the cold working step (200) is initiated in not greater than 60 hours, or not greater than 48 hours, or not greater than 36 hours, or not greater than 24 hours, or not greater than 20 hours, or not greater than 16 hours, or not greater than 12 hours, or less, after the completion of the solutionizing step (140). In one embodiment, the cold working step (200) is initiated within a few minutes, or less, of completion of the solutionizing step (140) (e,g., for continuous casting processes). In another embodiment, the cold working step (200) is initiated concomitant to completion of the solutionizing step (140) (e.g., for continuous casting processes),
  • the cold working step (200) may be completed one or more weeks or months after the completion of the solutionizing step (140).
  • a thermally treating step (300) is completed after the 'cold working step (200).
  • "Thermally treating" and the like means purposeful heating of an aluminum alloy body such that the aluminum alloy body reaches an elevated temperatui'e.
  • the thermal treatment step (300) may include heating the aluminum alloy body for a time and at a temperature sufficient to achieve a condition or property ⁇ e.g., a selected strength, a selected ductility, among others).
  • the thermally treating step (300) heats the aluminum alloy body to a temperature within a selected temperature range.
  • this temperature refers to the average temperature of the aluminum alloy body during the thermally treating step (300).
  • the thermally treating step (300) may include a plurality of treatment steps, such as treating at a first temperature for a first period of time, and treating at a second temperature for a second period of time.
  • the first temperature may be higher or lower than the second temperature, and the first period of time may be shorter or longer than the second period of time.
  • the thermally treating step (300) is generally completed such that the aluminum alloy body achieves / maintains a predominately unrecrystallized microstructure, as defined below. As described in further detail below, a predominately unrecrystallized microstructure may achieve improved properties.
  • the thermally treating step (300) generally comprises heating the aluminum alloy body to an elevated temperature, but below the recrystallization temperature of the aluminum alloy body, i.e., the temperature at which the aluminum alloy body would not achieve a predominately unrecrystallized microstructure.
  • the thermally treating step (300) may comprise heating the new HT aluminum alloy body to a temperature in the range of from 150°F to 425°F (or higher), but below the recrystallization temperature of the aluminum alloy body.
  • thermally treating especially in excess of 425°F, it may be necessary to limit the exposure period so that the produced aluminum alloy body realizes improved properties.
  • shorter thermal exposure periods may be required to realize the predominately unrecrystallized microstructure and/or other desired properties (e.g., absence of undue softening due to removal of dislocations from high temperature exposure).
  • the thermally treating step (300) may be completed in any suitable manner that maintains the aluminum alloy body at one or more selected temperature(s) for one or more selected period(s) of time (e.g., in order to achieve a desired / selected property or combination of properties).
  • the thermally treating step (300) is completed in an aging furnace, or the like.
  • the thermally treating step (300) is completed during a paint-bake cycle. Paint-bake cycles are used in the automotive and other industries to cure an applied paint by baking it for a short period of time (e.g., 5-30 minutes).
  • thermally treating step (300) may be completed during a coating cure step, or the like,
  • a method comprises (i) receiving a solutionized aluminum alloy body, and (ii) then cold working the aluminum alloy body, and (iii) then thermally treating the aluminum alloy body, wherein the cold working and the thermally treating steps are accomplished to achieve an improved property as compared to one or more of (a) the aluminum alloy body in the as-cold worked condition, (b) a reference version of the aluminum alloy body in the T6 temper, and (c) the aluminum alloy body in the T4 temper, such as achievement of any of the properties listed in the Properties section (Section H), above.
  • Such a method may be applicable to, and thus employed with, any of the aluminum alloy products described in the Product Applications section (Section I), below.
  • a method comprises (i) receiving an aluminum alloy body that has been solutionized and then cold worked by at least 25%, and (ii) then thermally treating the aluminum alloy body, wherein the cold working and the thermally treating steps are accomplished to achieve an improved property as compared to one or more of (a) the aluminum alloy body in the as-cold worked condition, (b) a reference version of the aluminum alloy body in the T6 temper, and (c) the aluminum alloy body in the T4 temper, such as achievement of any of the properties listed in the Properties section (Section H), above.
  • Such a method may be applicable to, and thus employed with, any of the aluminum alloy products described in the Product Applications section (Section I), below.
  • a method comprises (i) receiving a solutionized aluminum alloy body, and (ii) then cold working the aluminum alloy body, and (iii) then thermally treating the aluminum alloy body, wherein the cold working and the thermally treating steps are accomplished to achieve an improved property as compared to one or more of (a) the aluminum alloy body in the as-cold worked condition and (b) a reference version of the aluminum alloy body in the T6 temper, such as achievement of any of the properties listed in the Properties section (Section H), above.
  • Such a method may be applicable to, and thus employed with, any of the aluminum alloy products described in the Product Applications section (Section I), below.
  • a method comprises (i) receiving an aluminum alloy body that has been solutionized and then cold worked by at least 25%; and (ii) then thermally treating the aluminum alloy body, wherein the cold working and the thermally treating steps are accomplished to achieve an improved property as compared to one or more of (a) the aluminum alloy body in the as-cold worked condition and (b) a reference version of the aluminum alloy body in the T6 temper, such as achievement of any of the properties listed in the Properties section (Section H), above.
  • Such a method may be applicable to, and thus employed with, any of the aluminum alloy products described in the Product Applications section (Section I), below.
  • an aluminum alloys body is processed such that it achieves a preselected precursor condition during at least one of the cold working step (200) and the thermally treating step (300).
  • a preselected precursor condition is a condition that is selected in advance of production of the aluminum alloy body, and is a precursor to another condition (usually another known condition, such as a desired end condition or property of an aluminum alloy product).
  • an aluminum alloy supplier having completed cold working step (200), may supply an aluminum alloy body (e.g., a sheet) in a preselected underaged condition by subjecting the body to a preselected heating practice as part of the thermal treatment step (300).
  • a customer of the aluminum alloy supplier may receive this aluminum alloy body, and may further thermally process this aluminum alloy body, such as by warm forming the body into a predetermined shaped product, thereby completing the remaining portion of the thermal treatment step (300), and, in the process, further increasing the strength of the aluminum alloy body.
  • an aluminum alloy supplier may tailor their first heating step such that the combination of their first heating step and the customer's later second heating step produce an aluminum alloy body having predetermined properties (e.g., near peak strength, a predetermined combination of strength and ductility, among others).
  • predetermined properties e.g., near peak strength, a predetermined combination of strength and ductility, among others.
  • a thermally treating step (300) includes a first heating step (320) and a second heating step (340).
  • the first heating step (320) may be conducted to achieve a preselected condition (322) (e.g., a first selected condition).
  • the second heating step (340) may be conducted to achieve another preselected condition (342) (e.g., a second selected condition).
  • the first selected condition (322) may be selected, for example, to achieve a predetermined strength, a predetermined elongation, or a predetermined combination of strength and elongation, among other properties (330).
  • the selected condition (322) may be a predetermined underaged condition (324), a peaked aged condition (326), or a predetermined overaged condition (328).
  • the first heating step (320) is conducted for a first selected time and a first selected temperature to achieve the first selected condition (322).
  • the second heating step (340) may be selected to achieve a predetermined strength, a predetermined elongation, or a predetermined combination of strength and elongation, among other properties (350).
  • the second heating step (340) may be conducted to achieve a second selected condition (342), such as any of a predetermined underaged condition (344), a peak age condition (346), or a predetermined overage condition (348).
  • the second heating step (340) is conducted for a second selected time and a second selected temperature to achieve the second selected condition (342).
  • first heating step (320) may be tailored to achieve one or more preselected conditions
  • tailored aluminum alloy bodies may be produced in the first heating step (320) and at a first location for subsequent processing via the second heating step (340).
  • an aluminum alloy supplier may conduct a first heating step at a first location to achieve the selected condition (322).
  • the aluminum alloy supplier may then provide such aluminum alloy body to a customer (or other entity), who may subsequently conduct the second heating step (340) at a second location remote of the first location (e.g., to achieve the second selected condition (342)).
  • tailored aluminum alloy bodies having predetermined properties may be achieved.
  • a first heating step (320) may achieve a predetermined underaged condition (324).
  • This predetermined underaged condition may be within a predetermined amount of a peak strength of the aluminum alloy body, such as within a predetermined amount of an ultimate tensile strength and/or a tensile yield strength of the aluminum alloy body.
  • the predetermined underaged condition (324) is within 30% of a peak strength of the aluminum alloy body. In other embodiments, the predetermined underaged condition (324) is within 20%, or within 10%, or within 5%, or less, of a peak strength of the aluminum alloy body.
  • the predetermined underaged condition (324) is within 20 ksi of a peak strength of the aluminum alloy body. In other embodiments, the predetermined underaged condition (324) is within 15 ksi, or within 10 ksi, or within 5 ksi, or less, of a peak strength of the aluminum alloy body.
  • the aluminum alloy body, having been subjected to the first heating step (320) may be supplied from a supplier to a customer, and in the predetermined underaged condition (324).
  • the second heating step (340) may be completed by the customer to achieve a predetermined higher strength condition (372) relative to the prior predetermined underaged condition (324).
  • This predetermined higher strength condition (372) may be within a predetermined amount of a peak strength of the aluminum alloy body, such as a peak ultimate tensile strength and/or a peak tensile yield strength of the aluminum alloy body. In one embodiment, the predetermined higher strength condition (372) is within 15% of a peak strength of the aluminum alloy body. In other embodiments, the predetermined higher strength condition (372) is within 10%, or within 8%, or within 6%, or within 4%, or within 2%, or within 1%, or less, of a peak strength of the aluminum alloy body. Similarly, the predetermined higher strength condition (372) may be within 15 ksi of a peak strength of the aluminum alloy body.
  • the predetermined higher strength condition (372) may be within 10 ksi, or within 8 ksi, or within 6 ksi, or within 4 ksi, or within 2 ksi, or within 1 ksi, or less, of a peak strength condition of the aluminum alloy body.
  • a customer upon receipt of an aluminum alloy body that was subjected to a preparing step (100), a cold working step (200), and the first heating step (320), and thus being in a predetermined underaged condition (324), may subsequently conduct the second heating step (340) to achieve the second predetermined higher strength condition (372),
  • the second heating step (340) may be one or more of a warm forming process, a paint bake process, a drying process, and/or a tailored aging process conducted in an aging furnace, among others.
  • Such second heating step (340) processes may be conducted in any order as appropriate to the specific aluminum alloy body and its corresponding final form.
  • an aluminum alloy sheet may be supplied to an automotive manufacturer after completing the first heating step (320),
  • the automotive supplier may receive the aluminum alloy sheet in a predetermined selected condition (322) for later processing.
  • the automotive manufacturer may then form this part into a predetermined shaped product during at least a part of the second heating step (340) ("warm forming", which is defined in Section F, below).
  • warm forming which is defined in Section F, below.
  • an automotive manufacturer may paint bake and/or dry this predetermined shaped product, thereby subjecting the aluminum alloy body to additional thermal treatments as part of the second heating step (340) to achieve a second selected condition (342).
  • the automotive manufacturer may subject the predetermined shaped product to an aging furnace, or the like, before or after any of the other heating operations to tailor properties of the predetermined shaped product.
  • the automotive manufacturer may be able to receive a miinum alloy bodies in a first selected condition (322), so that the automotive manufacturer's subsequent thermal processing achieves a second selected condition, such as a higher strength condition.
  • the automotive manufacturer may conduct a second heating step (340) so as to facilitate achievement of a peak strength or near peak strength condition (346), as described above.
  • the automotive manufacturer may select a predetermined overaged (348) and/or underaged condition (344) to achieve a predetermined set of properties (350).
  • an automotive manufacturer may achieve higher ductility at slightly lower strength relative to a peak strength condition, thus facilitating a different set of properties relative to a peak strength condition (346).
  • underaged properties may provide a different set of mechanical properties that may be useful to an automotive manufacturer.
  • tailored aluminum alloy bodies having predetermined properties may be achieved, such as any of the properties described in the Properties section (Section H), below.
  • the aluminum alloy body may be supplied to a customer in either the as-cold worked condition or the T3 temper (i.e., the customer may receive the aluminum alloy after the cold working step (200), and without any thermal treatments being applied by the aluminum alloy supplier).
  • the customer may complete the thermal treatment step (300) and the optional final treatment step (400).
  • the optional final treatment may include the forming of the predetermined, shaped product (500) during the thermally treating step (300). That is to say, the customer completes all the thermal treatment steps, which may include a warm forming step (320'), Other or alternative thermal treatments may be employed by the customer, such as any of those illustrated in FIG. 2q-5, among others.
  • the steps prior to the first heating step (320) may also be completed at the first location. That is, the preparing the aluminum alloy body for post-solutionizing cold work step (100) may be completed at the first location and/or the cold working the aluminum alloy body step (200) may be completed at the first location. However, such processing steps are not required to be completed at the first location. Similarly, it is possible that all of the steps could be completed at a single location. Furthermore, while the above examples are explained relative to automotive products, such methodologies are applicable to many aluminum applications, such as any of the products described in the Product Applications section (Section I), below.
  • FIGS. 2q-l to 2q-5 have been described relative to achieving two preselected conditions (322), (342), it is not required that two selected conditions be employed.
  • an aluminum supplier may employ a first selected condition (322) based upon knowledge of a customer's processes to facilitate improvement of the customer's aluminum alloy products, and without the customer defining a second selected condition.
  • a first selected condition 322
  • only a single preselected condition is employed (e.g., selected condition (322)).
  • thermally treating step (300) when the thermally treating step (300) is completed at a single location, it may include a plurality of treatment steps, such as treating at a first temperature for a first period of time, and treating at a second temperature for a second period of time, and this first temperature may be higher or lower than the second temperature, and the first period of time may be shorter or longer than the second period of time, Similarly, each of heating steps (320) and (340) may also include a plurality of treatment steps, such as treating at a first temperature for a first period of time, and treating at a second temperature for a second period of time, and this first temperature may be higher or lower than the second temperature, and the first period of time may be shorter or longer than the second period of time.
  • a cold working step (200) includes a first cold working step (220) and a second cold working step (240), with the combination of the first cold working step (220) and second cold working step (240) inducing at least 25% cold work in the aluminum alloy body.
  • the first cold working step in of itself, induces at least 25% cold work in the aluminum alloy body.
  • the first cold working step (220) may be conducted to achieve a preselected condition (222) (e.g., a first selected condition).
  • the second cold working step (240) may be conducted to achieve another preselected condition (242) (e.g., a second selected condition).
  • the first selected condition (222) may be selected, lor example, to achieve a predetermined strength, a predetermined elongation, or a predetermined combination of strength and elongation, among other properties (230).
  • the second selected condition (232) may be selected, for example, to achieve a predetermined strength, a predetermined elongation, or a predetermined combination of strength and elongation, among other properties (250).
  • first cold working step (220) may be tailored to achieve one or more preselected conditions
  • tailored aluminum alloy bodies may be produced in the first cold working step (220) and at a first location for subsequent processing via the second cold working step (240) and thermal treatment step (300).
  • an aluminum alloy supplier may conduct a first cold working step at a first location to achieve the selected condition (222), The aluminum alloy supplier may then provide such aluminum alloy body to a customer (or other entity), who may subsequently conduct the second cold working step (240) and the thermally treating step (300) at a second location (or more locations) remote of the first location (e.g., to achieve the second selected condition (342)).
  • tailored aluminum alloy bodies having predetermined properties may be achieved, such as any of the properties described in the Properties section (Section H), below.
  • FIGS. 2q ⁇ 7 to 2q-8 have been described relative to achieving two preselected conditions (222), (242), it is not required that two selected conditions be employed.
  • an aluminum supplier may employ a first selected condition (222) based upon knowledge of a customer's processes to facilitate improvement of the customer's aluminum alloy products, and without the customer defining a second selected condition.
  • only a single preselected condition is employed (e.g., selected condition (222)).
  • a first cold working step and a first thermal treatment step may be completed at a first location, and a second cold working step and a second thermal treatment step may be completed at a second location to achieve one or more predetermined properties.
  • a first cold working step (220) and a first thermal treatment step (320) may be completed at a first location, and a second cold working step (240) and a second thermal treatment step (340) may be completed at a second location, with the combination of the first cold working step (220) and second cold working step (240) inducing at least 25% cold work in the aluminum alloy body.
  • the first cold working step in of itself, induces at least 25% cold work in the aluminum alloy body.
  • an aluminum alloy supplier may complete the first cold working step (220) and the first heating step (320), e.g., to achieve a preselected condition (322), such as a predetermined strength, a predetermined elongation, or a predetermined combination of strength and elongation (330), among others,
  • a preselected condition such as a predetermined strength, a predetermined elongation, or a predetermined combination of strength and elongation (330), among others.
  • a customer may receive the aluminum alloy body that was prepared for post- solutionizing cold work (100), first cold worked (220), and first heated (320).
  • the customer may then complete the second cold working step (240) and the second thermally treating step (340) to complete the cold working step (200) and thermally treating step (300), optionally with final treatments (400), and optionally to achieve another preselected condition (242) (e.g., a second selected condition).
  • a preselected condition e.g., a second selected condition.
  • tailored aluminum alloy bodies having predetermined properties may be achieved, such as any of the properties described in the Properties section (Section H), below.
  • FIG. 2q-9 has been described relative to achieving two preselected conditions (322), (342), it is not required that two selected conditions be employed.
  • an aluminum supplier may employ a first selected condition (322) based upon knowledge of a customer's processes to facilitate improvement of the customer's aluminum alloy products, and without the customer defining a second selected condition.
  • a first selected condition 322
  • only a single preselected condition is employed (e.g., selected condition (322)).
  • the combination of the cold working step (200) and the thermally treating step (300) are capable of producing aluminum alloy bodies having improved properties. It is believed that the combination of the high deformation of the cold working step (200) in combination with the appropriate thermally treatment conditions (300) produce a unique micro structure (see, Microstructure, below) capable of achieving combinations of strength and ductility that have been heretofore unrealized.
  • the cold working step (200) facilitates production of a severely deformed microstructure while the thermally treating step (300) facilitates precipitation hardening.
  • the cold working (200) is at least 25%, and preferably more than 50%, and when an appropriate thermal treatment step (300) is applied, improved properties may be realized.
  • the cold working (200) and thermally treating (300) steps are accomplished such that the aluminum alloy body achieves an increase in strength (e.g., tensile yield strength (R0.2) or ultimate tensile strength (R m )).
  • the strength increase may be realized in one or more of the L, LT or ST directions.
  • "Accomplished such that", "accomplished to achieve”, and the like, means that the referenced property or properties are determined after the referenced step or steps are concluded (e.g., properties are not measured in the middle of a thermally treating step, but are instead measured upon conclusion of the thermally treating step).
  • the cold working (200) and thermally treating ( 00) steps are accomplished such that the aluminum alloy body achieves an increase in strength as compared to a reference-version of the aluminum alloy body in the "as-cold worked condition".
  • the cold working (200) and thermally treating (300) steps are accomplished such that the aluminum alloy body achieves an increase in strength as compared to a reference- version of the aluminum alloy body in the T6 temper.
  • the cold working (200) and thermally treating (300) steps are accomplished such that the aluminum alloy body achieves an increase a higher R-value as compared to a reference-version of the aluminum alloy body in the T4 temper.
  • the "as-cold worked condition" means: (i) the aluminum alloy body is prepared for post-solutionizing cold work, (ii) the aluminum alloy body is cold worked, (iii) not greater than 4 hours elapse between the completion of the solutionizing step (1 0) and the initiation of the cold working step (200), and (iv) the aluminum alloy body is not thermally treated.
  • the mechanical properties of the aluminum alloy body in the as-cold worked condition should be measured within 4 - 14 days of completion of the cold working step (200).
  • the reference-version of the aluminum alloy body in the "as-cold worked condition” one would generally prepare an aluminum alloy body for post-solutionizing cold work (100), and then cold work the aluminum alloy body (200) according to the practices described herein, after which a portion of the aluminum alloy body is removed to determine its properties in the as-cold worked condition per the requirements described above. Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, after which its properties would be measured, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the as-cold worked condition and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). . Since the reference- ersion of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body.
  • the "T6 temper” and the like are designed an aluminum alloy body that has been solutionized and then thermally treated to a maximum strength condition (within 1 ksi of peak strength); applies to bodies that are not cold worked after solutionizing, or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits.
  • a maximum strength condition within 1 ksi of peak strength
  • aluminum alloy bodies produced in accordance with the new processes described herein may achieve superior as compared to the aluminum alloy body in a T6 temper.
  • a reference-version of the aluminum alloy body in a T6 temper one would prepare an aluminum alloy body for post-solutionizing cold work (100), after which a portion of the aluminum alloy body would be processed to a T6 temper (i.e., a referenced aluminum alloy body in the T6 temper). Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the T6 temper and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). Since the reference- version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body.
  • the reference-version of the aluminum alloy body may require work (hot and/or cold) before the solutionizing step (140) to place the reference- ersion of the aluminum alloy body in a comparable product form to the new aluminum alloy body (e.g., to achieve the same final thickness for rolled products).
  • the "T4 temper” and the like means an aluminum alloy body that has been solutionized and then naturally aged to a substantially stable condition; applies to bodies that are not cold worked after solutionizing, or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits.
  • To produce a reference- version of the aluminum alloy body in a T4 temper one would prepare an aluminum alloy body for post-solutionizing cold work (100), after which a portion of the aluminum alloy body would be allowed to naturally age to a T4 temper (i.e., a referenced aluminum alloy body in the T4 temper).
  • Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the T4 temper and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness), Since the reference-version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body.
  • the reference-version of the aluminum alloy body may require work (hot and/or cold) before the solutionizing step (140) to place the reference- version of the aluminum alloy body in a comparable product form to the riew aluminum alloy body (e.g., to achieve the same thickness for rolled products).
  • the "T3 temper” and the like means an aluminum alloy body that has been solutionized, cold worked and then naturally aged (i.e., no thermal treatment has been applied at the time properties are measured).
  • To produce a reference- version of the aluminum alloy body in a T3 temper one would prepare an aluminum alloy body for post-solutionizing cold work (100), after which the aluimnum alloy body is naturally aged (room temperature aged) until the strength stabilizes, usually after a few days or weeks.
  • Another portion of the aluminum alloy body would be then thermally treated in accordance with the new processes described herein, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the T3 temper and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). Since the reference-version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body.
  • the "T87 temper” and the like means an aluminum alloy body that has been solutionized, cold worked 10% (rolled or stretched), and then thermally treated to a maximum strength condition (within 1 ksi of peak strength).
  • aluminum alloy bodies produced in accordance with the new processes described herein may achieve superior properties over a comparable aluminum alloy body in a T87 temper.
  • To produce a reference-version of the aluminum alloy body in a T87 temper one would prepare an aluminum alloy body for post-solutionizing cold work (100), after which a portion of the aluminum alloy body would be processed to a T87 temper (i.e., a referenced aluminum alloy body in the T87 temper).
  • Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the T87 temper and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). Since the reference-version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body.
  • the reference-version of the aluminum alloy body may require work (hot and/or cold) before the solutionizing step (140) to place the reference-version of the aluminum alloy body in a comparable product form to the new aluminum alloy body (e.g., to achieve the same thickness for rolled products).
  • the cold working step is initiated at a temperature of not greater than 400° (e.g., at a temperature of not greater than 250°F) and the thermally treating step (300) is conducted at a temperature of at least 150°F.
  • the thermally treating step (300) and cold working step (200) may overlap (partially or fully) so long as they are conducted such that the new aluminum alloy bodies described herein are produced.
  • the thermally treating step (300) may be completed concomitant to the cold working step (200).
  • Recrystallization The cold working (200) and thermally treating (300) steps may be accomplished such that the aluminum alloy body achieves / maintains a predominately unrecrystallized microstructure.
  • a predominately unrecrystallized microstructure means that the aluminum alloy body contains less than 50% of first type grains (by volume fraction), as defined below.
  • An aluminum alloy body has a crystalline microstructure.
  • a "crystalline microstructure” is the structure of a polycrystalline material.
  • a crystalline microstructure has crystals, referred to herein as grains, "Grains" are crystals of a polycrystalline material,
  • First type grains means those grains of a crystalline microstructure that meet the "first grain criteria”, defined below, and as measured using the OIM (Orientation Imaging Microscopy) sampling procedure, described below. Due to the unique microstructure of the aluminum alloy body, the present application is not using the traditional terms “recrystallized grains” or “unrecrystallized grains”, which can be ambiguous and the subject of debate, in certain circumstances. Instead, the terms “first type grains” and “second type grains” are being used where the amount of these types of grains is accurately and precisely determined by the use of computerized methods detailed in the OIM sampling procedure. Thus, the term “first type grains” includes any grains that meet the first grain criteria, and irrespective of whether those skilled in the art would consider such grains to be unrecrystallized or recrystallized.
  • the OIM analysis is to be completed from the T/4 (quarter- plane) location to surface of the L-ST plane.
  • the size of the sample to be analyzed will generally vary by gauge.
  • the OIM samples Prior to measurement, the OIM samples are prepared by standard metallographic sample preparation methods. For example, the OIM samples are generally polished with Buehler Si-C paper by hand for 3 minutes, followed by polishing by hand with a Buehler diamond liquid polish having an average particle size of about 3 microns. The samples are anodized in an aqueous fluoric- boric solution for 30-45 seconds. The samples are then stripped using an aqueous phosphoric acid solution containing chromium trioxide, and then rinsed and dried.
  • the software used is TexSEM Lab OIM Data Collection Software version 5,31 (EDAX Inc., New Jersey, U.S.A.), which is connected via FIREWIRE (Apple, Inc., California, U.S.A.) to a DigiView 1612 CCD camera (TSL/EDAX, Utah, U.S.A.).
  • the SEM is a JEOL JSM6510 (JEOL Ltd. Tokyo, Japan),
  • OIM run conditions are 70° tilt with a 18 mm working distance and an accelerating voltage of 20 kV with dynamic focusing and spot size of 1 times 10 "7 amp
  • the mode of collection is a square grid. A selection is made such that orientations are collected in the analysis (i.e., Hough peaks information is not collected).
  • the area size per scan i.e., the frame
  • the collected data is output in an *.osc file. This data may be used to calculate the volume fraction of first type grains, as described below.
  • First grain criteria Calculated via grain orientation spread (GOS) with a grain tolerance angle of 5°, minimum grain size is three (3) data points, and confidence index is zero (0). All of '''apply partition before calculation”, “include edge grains”, and “ignore twin boundary definitions” should be required, and the calculation should be completed using "grain average orientation”. Any grain whose GOS is ⁇ 3° is a first type grain. If multiple frames are used, the GOS data are averaged.
  • GOS grain orientation spread
  • First grain volume means the volume fraction of first type grains of the crystalline material
  • the aluminum alloy body generally comprises a predominately unrecrystallized microstructure, i.e., FGV ⁇ 0.50 and URX% > 50%.
  • the aluminum alloy body contains (by volume fraction) not greater than 0.45 first type grains (i.e., the aluminum alloy . body is at least 55% unrecrystallized (URX% > 55%), per the definitions provided above).
  • the aluminum alloy body may contain (by volume fraction) not greater than 0.40 first type grains (URX% > 60%), or not greater than 0.35 first type grains (URX% > 65%), or not greater than 0.30 first type grains (URX% > 70%), or not greater than 0.25 first type grains (U R x% > 75%), or not greater than 0.20 first type grains (URX% > 80%), or not greater than 0.15 first type grains (URX% > 85%), or not greater than 0,10 first type grains (U R % > 90%), or less. //. Texture
  • the aluminum alloy body may achieve a unique micro structure. This unique microstructure may be illustrated by the R-values of the aluminum alloy body derived from crystallographic texture data.
  • the microstructure of an aluminum alloy body relates to its properties (e.g., strength, ductility, toughness, corrosion resistance, among others).
  • R-values are generated according to the R- value generation procedure, described below.
  • An x-ray generator with a computer-controlled pole figure unit e.g., Rigaku Ultima III diffractometer (Rigaku USA, The Woodlands, TX) and data collection software and ODF software for processing pole figure data (e.g., Rigaku software included with the Rigaliu diffractometer) is used.
  • the reflection pole figures are captured in accordance with "Elements of X-ray Diffraction" by B.D. Cullity, 2 nd edition 1978 (Addison- Wesley Series in Metallurgy and Materials) and the Rigaliu User Manual for the Ultima III Diffractometer and Multipurpose Attachment (or other suitable manual of other comparable diffractometer equipment).
  • sample preparation The pole figures are to be measured from the T/4 location to surface.
  • the sample used for R-value generation is (preferably) 7/8 inch (LT) by 1 1 ⁇ 4 inches (L). Sample size may vary based on measurement equipment.
  • the sample Prior to measurement of the R- alue, the sample may be prepared by:
  • the sample should be oscillated 2 cm per second to achieve a larger sampling area for improved sampling statistics
  • the output data are usually converted to a format for input into ODF software.
  • the ODF software normalizes the data, calculates the ODF, and recalculates normalized pole figures. From this information, R-values are calculated using the Taylor-Bishop-Hill model ⁇ see, Kuroda, M. et al., Texture optimization of rolled aluminum alloy sheets using a genetic algorithm, Materials Science and Engineering A 385 (2004) 235-244 and Man, Chi-Sing, On the r-value of textured sheet metals, International Journal of Plasticity 18 (2002) 1683-1706).
  • Normalized R-value and the like means the R-value as normalized by the R-value of the RV-control sample at an angle of 0° relative to the rolling direction. For example, if the RV-control sample achieves an R-value of 0.300 at an angle of 0° relative to the rolling direction, this and all other R-values would be normalized by dividing by 0.300.
  • RV-control sample and the like means a control sample taken from a reference- version aluminum alloy body in a T4 temper (defined above).
  • Rolling direction and the like means the L-direction for rolled products ⁇ see, FIG. 13).
  • Rolling direction and in the context of R-values "rolling direction” and the like means the principle direction of extension (e.g., the extrusion direction).
  • the various R-values of a material are calculated from an angle of 0° to an angle of 90° relative to the rolling direction, and in increments of 5°.
  • orientation angle is sometimes used to refer to the phrase "angle relative to the rolling direction”.
  • Maximum normalized R- value and the like means the maximum normalized R- value achieved at any angle relative to the rolling direction.
  • Max RV angle and the like means the angle at which the maximum normalized R- value is achieved.
  • FIG. 10 also contains the normalized R-values for aluminum alloy bodies with 1 1%, 35% and 60% cold work.
  • the high cold worked aluminum alloy bodies achieve higher R-values than the RV-control sample, especially between orientation angles of 20° and 70° relative to the rolling direction.
  • a maximum normalized R-value of 5.196 is achieved at a max RV angle of 50°.
  • the RV-control sample achieves a maximum normalized R-valut? of 1.030 at a max RV angle of 5°.
  • an aluminum alloy body processed in accordance with the new methods described herein may achieve a maximum normalized R-value of at least 2.0.
  • the new aluminum alloy body may achieve a maximum normalized R-value of at least 2.5.
  • the new aluminum alloy body may achieve a maximum normalized R-value of at least 3.0, or at least 3.5, or at least 4.0, or at least 4.5, or at least 5,0, or at least 5.5, or at least 6.0, or higher.
  • the maximum normalized R-value may be achieved at an orientation angle of from 20° to 70°.
  • the maximum normalized R-value may be achieved at an orientation angle of from 30° to 70°, In other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 35° to 65°. In yet other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 40° to 65°. In yet other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 45° to 60°. In other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 45° to 55°.
  • an aluminum alloy body processed in accordance with the new methods described herein may achieve a maximum normalized R-value that is at least 200% higher than the RV-control sample at the max RV angle of the new aluminum alloy body.
  • the normalized R-value of the new aluminum alloy body is compared to the normalized R-value of the RV-control sample at the angle where the max RV angle of the new aluminum alloy body occurs. For example, as shown in FIG.
  • an aluminum alloy body may achieve a maximum normalized R-value that is at least 250% higher than the RV-control sample at the max RV angle of the new aluminum alloy body.
  • the aluminum alloy body may achieve a maximum normalized R-value that is at least 300% higher, or at least 350% higher, or at least 400% higher, or at least 450% higher, or at least 500% higher, or at least 550% higher, or at least 600% higher, or at least 650% higher, or at least 700% higher, or more, than the RV-control sample at the max RV angle of the aluminum alloy body.
  • an aluminum alloy body processed in accordance with the new methods described herein may achieve a maximum normalized R-value that is at least 200% higher than the maximum normalized R-value of the RV-control sample.
  • the maximum normalized R-value of the new aluminum alloy body is compared to the maximum normalized R-value of the RV-control sample, irrespective of the angle at which the maximum normalized R-values occur.
  • the 85% cold worked aluminum alloy body alloy realizes a maximum normalized R-value of 5.196 at an orientation angle of 50°.
  • the maximum normalized R-value of the RV-control sample is 1.030 at an orientation angle of 5°.
  • an aluminum alloy body may achieve a maximum normalized R- value that is at least 250% higher than the maximum normalized R-value of the RV-control sample. In other embodiments, the aluminum alloy body may achieve a maximum normalized R-value that is at least 300% higher, or at least 350% higher, or at least 400% higher, or at least 450% higher, or at least 500% higher, or more, than the maximum normalized R-value of the RV-control sample.
  • FIGS. 1 lb-1 le Optical micrographs of some new HT aluminum alloys bodies produced in accordance with the new processes described herein are illustrated in FIGS. 1 lb-1 le.
  • FIG. 1 1a is a microstructure of a reference-version of the aluminum alloy body in the T6 temper.
  • FIGS, l lb-l le are microstructures of new aluminum alloy bodies having 1 1%, 35%, 60% and 85% cold work, respectively, These micrographs illustrate some aspects of the unique microstructures that may be attained using the new processes described herein. As illustrated, the grains of the new aluminum alloy bodies appear to be non-equiaxed (elongated) grains.
  • FIGS l lf-l lg are micrographs of Alloys CC8 and CC 18 of Example 17, which were continuously cast per Section (A)(i).
  • the new HT aluminum alloy body may be subjected to various optional final treatment(s) (400).
  • the new HT aluminum alloy body may be subjected to various additional working or finishing operations (e.g., (i) forming operations, (ii) flattening or straightening operations that do not substantially affect mechanical properties, such as stretching, and/or (iii) other operations, such as machining, anodizing, painting, polishing, buffing).
  • the optional final treatment(s) step (400) may be absent of any purposeful / meaningful thermal treatment(s) that would materially affect the micro structure of the aluminum alloy body (e.g., absent of any anneal steps). Thus, the microstructure achieved by the combination of the cold working (200) and thermally treating (300) steps may be retained.
  • one or more of the optional final treatment(s) (400) may be completed concomitant to the thermal treatment step (300).
  • the optional final treatment(s) step (400) may include forming, and this forming step may be completed concomitant to (e.g., contemporaneous to) the thermal treatment step (300).
  • the aluminum alloy body may be in a substantially final form due to concomitant forming and thermal treatment operations (e.g., forming automotive door outer and/or inner panels, body-in- white components, hoods, deck lids, and similar components during the thermal treatment step, among the other products listed in the Product Applications section (Section I), below).
  • an aluminum alloy body is in the form of a predetermined shaped product after the forming operation.
  • a thermal treatment step (300) may consist of the warm forming step (320'), and a predetermined shaped product may be produced.
  • optional final treatment(s) (400) may include forming operations (e.g., room temperature or warm forming operations for forming predetermined shaped products), some work (warm or cold) may be induced in the body due to such forming operations, but such forming operations are not included in the definition of "cold working" relative to step (200) when such forming operations either (i) occur after the thermally treatment step (300) is accomplished (completed), or (ii) occur before, during, or concomitant to the thermal treatment step (300) (i.e., before the thermal treatment step is accomplished (completed)), but induce less than 0.3322 equivalent plastic strain (i.e., less than 25% CW, per Table 1, above).
  • forming operations e.g., room temperature or warm forming operations for forming predetermined shaped products
  • some work warm or cold
  • some work may be induced in the body due to such forming operations, but such forming operations are not included in the definition of "cold working" relative to step (200) when such forming operations either (
  • any forming operation that occurs at cold working temperature(s) (defined above) and induces at least 0.3322 equivalent plastic strain after solutionizing and prior to completion of the thermal treatment step is "cold working", per above, and is thus included in the definition of cold working step (200), and not in the definition of the optional final treatment step (400).
  • a "predetermined shaped product” and the like means a product that is formed into a shape via a shape forming operation (e.g., drawing, ironing, warm forming, flow forming, shear forming, spin forming, doming, necking, flanging, threading, beading, bending, seaming, stamping, hydroforming, and curling, among others), and which shape was determined in advance of the shape forming operation (step).
  • a shape forming operation e.g., drawing, ironing, warm forming, flow forming, shear forming, spin forming, doming, necking, flanging, threading, beading, bending, seaming, stamping, hydroforming, and curling, among others
  • predetermined shaped products examples include automotive components (e.g., hoods, fenders, doors, roofs, and trunk lids, among others) and containers (e.g., food cans, bottles, among others), consumer electronic components (e.g., as laptops, cell phones, cameras, mobile music players, handheld devices, computers, televisions, among others), and many other aluminum alloy products described in the Product. Applications section (Section I), below.
  • predetermined shaped products do not include mere sheet or plate products as produced after cold rolling, since rolling is not a "forming operation" as defined herein, and rolled products are thus not "formed into a shape by a shape forming operation”.
  • the predetermined shaped product is in its final product form after the forming operation.
  • the forming operation utilized to produce "predetermined shaped products" may occur before, after or concomitant to the thermally treating step (300), such as described in the Thermal Treatment section (Sections C, subsection 0-
  • a predetermined shaped product is a product produced by flow forming.
  • Flow forming is an incremental metal forming technique in which a disk or tube of metal is formed over a mandrel by one or more rollers using pressure, where the roller deforms the workpiece, forcing it against the mandrel, usually both axially lengthening the workpiece while radially thinning the workpiece.
  • bases
  • the forming operation may be completed before, during, or after the thermal treatment step (300).
  • the forming operation is completed concomitant to the thermal treatment step (300), and thus may occur at a temperature of from ' 150°F to below the recrystallization temperature of the rolled aluminum alloy product.
  • These forming operations are referred to herein as "warm forming" operations.
  • a warm forming operation occurs at a temperature of from 200°F to 5 SOT.
  • a warm forming operation occurs at a temperature of from 250°F to 450°F.
  • warm forming may be used to produce predetermined shaped products and in a predetermined condition, as described in the Thermal Treatment section (Section C), above, including any of the embodiments illustrated in FIGS.
  • the "as- received condition” and the like includes the partially cold worked condition (per step 220), the as-cold worked condition (full completion of step 200, and per the definition of as-cold worked condition, below), the T3 condition (full completion of step 200, and per the definition of T3 temper, below), or the partially thermally treated condition (per step 320), and combinations thereof.
  • the improved properties may be any of the improved properties described in the Properties ection (Section H), below.
  • Warm forming may facilitate production of defect-free predetermined shaped products.
  • Defect-free means that the components are suitable for use as a commercial product, and thus may have little (insubstantial) or no cracks, wrinkles, Ludering, thinning and orange peel, to name a few.
  • room temperature forming may be used to produce defect-free predetermined shaped products.
  • the forming operation may occur at temperatures of less than 150°F, such as at ambient conditions ("room temperature forming"), and thus are riot a part of the thermal treatment step (300).
  • the above-described forming operations typically apply a strain to an aluminum alloy body (e.g., applying a stain to a rolled aluminum alloy product, such as an aluminum alloy sheet or aluminum alloy plate) to form the aluminum alloy body into the predetermined shaped product.
  • the amount of strain may vary during the forming operation, but the maximum amount of strain applied during the forming operation is usually at least 0,01 EPS (equivalent plastic strain). In one embodiment, the maximum amount of strain applied during the forming operation is at least 0.05 EPS. In another embodiment, the maximum amount of strain applied during the forming operation is at least 0.07 EPS. In yet another embodiment, the maximum amount of strain applied during the forming operation is at least 0.10 EPS.
  • the maximum amount of strain applied during the forming operation is at least 0.15 EPS. In yet another embodiment, the maximum amount of strain applied during the forming operation is at least 0.20 EPS. In another embodiment, the maximum amount of strain applied during the forming operation is at least 0.25 EPS. In yet another embodiment, the maximum amount of strain applied during the forming operation is at least 0,30 EPS. In any of these embodiments, the maximum amount of strain applied during the forming operation may be less than 0.3322 EPS,
  • the predetermined shaped product may be distributed and/or otherwise used by the user of the forming step.
  • an automotive manufacturer may form an automotive component, and then assemble a vehicle using the automotive component
  • An aerospace vehicle manufacturer may form an aerospace component, and then assemble an aerospace vehicle using the aerospace component.
  • a container manufacturer may form a container, and then provide such container to a food or beverage distributor for filing and distribution for consumption.
  • the new HT aluminum alloy body is made from an aluminum alloy having 0.2 - 2.0 wt. % Mg, 0.1 - 1.5 wt. % Si, 0.01 to 1.0 wt. % Fe, 0.1 - 1.0 wt. % Cu, optionally up to 1 ,5 wt. % Mn, and optionally up to 1.5 wt, % zinc, with at least one of the magnesium, the silicon, the iron, the copper, the optional manganese and the optional zinc, being the predominate alloying ingredient, and, when Si+Cu ⁇ 0.60 wt. %, then Fe+Mn ⁇ 1.5 wt. %.
  • the new HT alloy generally includes 0.2 - 2.0 wt. % Mg. In one embodiment, the new HT aluminum alloy includes at least 0.40 wt. % Mg. In one embodiment, the new HT aluminum alloy includes at least 0.60 wt. % Mg. In one embodiment, the new HT aluminum alloy includes not greater than 1.7 wt. % Mg. In one embodiment, the new HT aluminum alloy includes not greater than 1.5 wt. % Mg. In one embodiment, at least one of the Si and the Mg is predominate alloying element of the aluminum alloy body other than the aluminum, In one embodiment, the Mg is predominate alloying element of the aluminum alloy body other than the aluminum.
  • the new HT aluminum alloy generally includes 0.1 - 1.5 wt, % Si, In one embodiment, the new HT aluminum alloy includes at least about 0.20 wt. % Si. In one embodiment, the new HT aluminum alloy includes at least about 0.30 wt, % Si. In one embodiment, the new HT aluminum alloy includes at least about 0.40 wt. % Si. In one embodiment, the new HT aluminum alloy includes not greater than about 1.1 wt. % Si. In one embodiment, the new HT aluminum alloy includes not greater than about 0.8 wt. % Si. In one embodiment, at least one of the Si and the Mg is predominate alloying element of the aluminum alloy body other than the aluminum. In one embodiment, the Si is predominate alloying element of the aluminum alloy body other than the aluminum.
  • the new HT alloy generally includes 0.01 - 1.0 wt. % Fe. In one embodiment, the new HT aluminum alloy includes at least 0.10 wt. % Fe. In one embodiment, the new HT aluminum alloy includes at least 0.20 wt. % Fe. In one embodiment, the new HT aluminum alloy includes at least 0.30 wt. % Fe. In one embodiment, the new HT aluminum alloy includes at least 0.50 wt. % Fe. In one embodiment, the new HT aluminum alloy includes at least 0.60 wt. % Fe. In one embodiment, the new HT aluminum alloy includes not greater than 0.80 wt. % Fe. In one embodiment, the Fe is predominate alloying element of the aluminum alloy body other than the aluminum.
  • the new HT alloy generally includes 0.1 - 1.0 wt. % Cu. In one embodiment, the new HT aluminum alloy includes at least about 0.20 wt. % Cu. In one embodiment, the new HT aluminum alloy includes at least about 0.30 wt. % Cu. In one embodiment, the new HT aluminum alloy includes at least about 0.40 wt. % Cu. In one embodiment, the new HT aluminum alloy includes at least about 0.50 wt. % Cu. In one embodiment, the new HT aluminum alloy includes at least about 0.60 wt, % Cu. In one embodiment, the Cu is predominate alloying element of the aluminum alloy body other than the aluminum.
  • the alloy contains increased levels of Si+Cu, which may increase strength.
  • the aluminum alloy contains an amount of Si and Cu such that Si+Cu > 0,4 wt. %, In another embodiment, the aluminum alloy contains an amount of Si and Cu such that Si+Cu > 0.6 wt. %. In yet another embodiment, the aluminum alloy contains an amount of Si and Cu such that Si+Cu > 0,8 wt. %. In another embodiment, the aluminum alloy contains an amount of Si and Cu such that Si+Cu > 1.0 wt, %. In yet another embodiment, the aluminum alloy contains an amount of Si and Cu such that Si+Cu > 1 ,2 wt, %, In another embodiment, the aluminum alloy contains an amount of Si and Cu such that Si+Cu > 1.4 wt. %.
  • the combined amount of Si and Cu is at least 0.45 wt, %, and the aluminum alloy body achieves a long-transverse tensile yield strength of at least 50 ksi. In another embodiment the combined amount of Si and Cu is at least 0.80 wt, %, and the aluminum alloy body achieves a long-transverse tensile yield strength of at least 55 ksi. In yet another embodiment, the combined amount of Si and Cu is at least 1.30 wt. %, and the aluminum alloy body achieves a long-transverse tensile yield strength of at least 60 ksi. In another embodiment, the combined amount of Si and Cu is at least 1.45 wt. %, and wherein the aluminum alloy body achieves a long-transverse tensile yield strength of at least 65 ksi.
  • the new HT alloy may optionally include up to 1.5 wt. % Mn.
  • the new HT aluminum alloy includes manganese, and in these embodiments the new HT aluminum alloy includes at least 0.01 wt. % Mn. In one embodiment, the new HT aluminum alloy includes at least 0.10 wt. % Mn. In another embodiment, the new HT aluminum alloy 0.25 wt. % Mn. In one embodiment, the new HT aluminum alloy includes at least 0.35 wt. % Mn. In one embodiment the new HT aluminum alloy includes not greater than 1 ,35 wt. % Mn. In one embodiment, the new HT includes not greater than 1.2 wt. % Mn. In one embodiment, the new HT includes not greater than 1.1 wt. % Mn.
  • the Mn is predominate alloying element of the aluminum alloy body other than the aluminum.
  • the aluminum alloy may comprise at least 0.50 wt. % Mn, such as at least 0.75 wt.% Mn, or at least 1.0 wt. % Mn.
  • manganese is included in the alloy as an impurity, and in these embodiments is present at levels of less than 0.01 wt. % Mn,
  • the new HT alloy may optionally include up to 1.5 wt. % Zn, such as up to 1.25 wt. % Zn, or up to 1.0 wt. % Zn.
  • the new HT aluminum alloy includes zinc, and in these embodiments the new HT aluminum alloy includes at least 0.05 wt. % Zn. In one embodiment, the new HT aluminum alloy includes at least 0.25 wt. % Zn. In one embodiment, the new HT aluminum alloy includes at least 0.5 wt. % Zn.
  • the Zn is predominate alloying element of the aluminum alloy body other than the aluminum.
  • the new HT aluminum alloy includes at least 0.5 wt. % Zn. In one embodiment, the new HT aluminum alloy includes at least 0.75 wt. % Zn. In another embodiment, the new HT aluminum alloy includes at least 1 ,0 wt. % Zn.
  • zinc is included in the alloy as an impurity, and in these embodiments is present at levels of 0.04 wt, % Zn, or less.
  • the new HT aluminum alloy may also include secondary elements, tertiary elements and/or other elements, as defined below.
  • the new HT aluminum alloy may include a secondary element,
  • the secondary element is nickel.
  • the new HT aluminum alloy includes nickel.
  • this secondary element in combination with the primary elements, may promote one or both of a strain hardening response and a precipitation hardening response.
  • the new HT aluminum alloy may realize an improved combination of properties, such as improved strength (e.g., as compared to the new HT aluminum alloy body in the as cold worked condition).
  • the new HT aluminum alloy When nickel is used, the new HT aluminum alloy generally includes at least 0,05 wt. % Ni, In one embodiment, the new HT aluminum alloy includes at least 0.25 wt. % Ni. In one embodiment, the new HT aluminum alloy includes at least 0.5 wt. % Ni. The new HT aluminum alloy generally includes not greater than 2.0 wt. % Ni, such as not greater than 1 ,5 wt. % Ni. In other embodiments, nickel is included in the alloy as an impurity, and in these embodiments is present at levels of 0.04 wt. % Ni, or less.
  • the new HT aluminum alloys may include a variety of tertiary elements for various purposes, such as to enhance mechanical, physical or corrosion properties (i.e, strength, toughness, fatigue resistance, corrosion resistance), to enhance properties at elevated temperatures, to facilitate casting, to control cast or wrought grain structure, and/or to enhance machinability, among other purposes.
  • these tertiary elements may include one or more of: (i) up to 3.0 wt. % Ag, (ii) up to 2.0 wt. % each of one or more of Li, Sn, Bi, Pb, and Cd, (iii) up to 1.0 wt.
  • a tertiary element is usually contained in the alloy by an amount of at least 0.01 wt. %.
  • the new HT aluminum alloy generally contains low amounts of "other elements” (e.g., casting aids and impurities), Other elements means any other element of the periodic table that may be included in the new HT aluminum alloy, except for the aluminum, the iron, the manganese, the magnesium, the silicon, the copper, the secondary elements (when included), and the tertiary elements (when included). When any element of the secondary and/or tertiary elements is contained within the alloy only as an impurity, such elements fall within the scope of "other elements", except for iron.
  • other elements e.g., casting aids and impurities
  • a new HT aluminum alloy includes nickel as an impurity (i.e., at or below 0.04 wt, % Ni for purposes of this patent application), and not as an alloying addition, the nickel would fall within the scope of "other elements”.
  • a new HT aluminum alloy includes zinc as an impurity (i.e., at or below 0.04 wt. % Zn for purposes of this patent application), and not as an alloying addition, the zinc would fall within the scope of "other elements”.
  • the aluminum alloy body contains not more than 0.25 wt. % each of any element of the other elements, with the total combined amount of these other elements not exceeding 0.50 wt. %, In one embodiment, each one of these other elements, individually, does not exceed 0, 10 wt. % in the new FIT aluminum alloy, and the total combined amount of these other elements does not exceed 0.35 wt. % ; in the new HT aluminum alloy. In another embodiment, each one of these other elements, individually, does not exceed 0.05 wt. % in the new HT aluminum alloy, and the total combined amoutit of these other elements does not exceed 0.15 wt. % in the new HT aluminum alloy. In another embodiment, each one of these other elements, individually, does not exceed 0.03 wt. % in the new HT aluminum alloy, and the total combined amount of these other elements does not exceed 0.1 wt. % in the new HT aluminum alloy.
  • the total amount of the primary, secondary, and tertiary alloying elements should be chosen so that the aluminum alloy body can be appropriately solutionized (e.g., to promote hardening while restricting the amount of constituent particles).
  • the total amount of the primary, secondary, and tertiary alloying elements should be chosen so that the aluminum alloy body can be appropriately solutionized (e.g., to promote hardening while restricting the amount of constituent particles),
  • the new HT aluminum alloys contains sufficient solute to promote at least one of a strain hardening response and a precipitation hardening response to achieve the desired strength level.
  • higher levels of silicon, copper, manganese and/or magnesium may be used to at least partially promote the strain hardening response and/or precipitation hardening response, and thus may be included in the alloy in the amounts described above.
  • the new HT aluminum alloy contains sufficient magnesium to promote a hardening response.
  • the new HT aluminum alloy generally contains at least 1 ,1 wt. % Mg, such as at least 1.2 wt. % Mg, or at least 1.3 wt.
  • the new HT aluminum alloy contains sufficient manganese to promote a hardening response.
  • the new HT aluminum alloy generally contains at least 0.3 wt. % Mn, such as at least 0.6 wt. % Mg, or at least 0.9 wt. % Mn.
  • the new HT aluminum alloy includes an amount of alloying elements that leaves the new HT aluminum alloy free of, or substantially free of, soluble constituent particles after solutionizing. In one embodiment, the new HT aluminum alloy includes an amount of alloying elements that leaves the aluminum alloy with low amounts of (e.g., restricted / minimized) insoluble constituent particles after solutionizing, In other embodiments, the new HT aluminum alloy may benefit from controlled amounts of insoluble constituent particles.
  • the new HT aluminum alloy bodies produced by the new processes described herein may achieve (realize) an improved combination of properties.
  • the cold working (200) and the thermally treating (300) steps may be accomplished to achieve an increase in strength as compared to a reference -vers ion of the aluminum alloy body in the as cold-worked condition and/or the T6 temper (as defined above), Strength properties are generally measured in accordance with ASTM E8 and B557, but may be measured in accordance with other applicable standards, as appropriate to the product form (e.g., use of NASM 1312-8 and/or NASM 1312-13 for fasteners).
  • the aluminum alloy body achieves at least a 5% increase in strength (TYS and/or UTS) relative to a reference-version of the aluminum alloy body in the T6 condition (temper). In one embodiment, the aluminum alloy body achieves at least a 6% increase in tensile yield strength relative to a reference-version of the aluminum alloy body in the T6 condition, In other embodiments, the aluminum alloy body achieves at least a 7% increase in tensile yield strength, or at least a 8% increase in tensile yield strength, or at least a 9% increase in tensile yield strength, or at least a 10% increase in tensile yield strength, or at least a 1 1% increase in tensile yield strength, or at least a 12% increase in tensile yield strength, or at least a 13% increase in tensile yield strength, or at least a 14% increase in tensile yield strength, or at least a 15% increase in tensile yield strength, or at least a 16%
  • the aluminum alloy body may achieve at least a 6% increase in ultimate tensile strength relative to the aluminum alloy body in the T6 condition. In other embodiments, the aluminum alloy body may achieve at least a 7% increase in ultimate tensile strength, or at least an 8% increase in ultimate tensile strength, or at least a 9% increase in ultimate tensile strength, or at least a 10% increase in ultimate tensile strength, or at least an 1 1% increase in ultimate tensile strength, or at least a 12% increase in ultimate tensile strength, or at least a 13% increase in ultimate tensile strength, or at least a 14% increase in ultimate tensile strength, or at least a 15% increase in ultimate tensile strength, or at least a 16% increase in ultimate tensile strength, or at least a 17% increase in ultimate tensile strength, or at least an 18% increase in ultimate tensile strength, or at least a 19% increase in ultimate tensile strength
  • an aluminum alloy fastener may achieve at least a 2% increase in shear strength relative to a reference version of the aluminum alloy fastener , wherein the reference version of the aluminum alloy fastener is in one of a T6 temper and a T87 temper, wherein the shear strength is tested in accordance with NASM 1312-13.
  • the aluminum alloy fastener may achieve at least a 4% increase in shear strength, or at least a 6% increase in shear strength, or at least an 8% increase in shear strength, or at a 10% increase in shear strength, or at least a 12%» increase in shear strength, or at least a 14% increase in shear strength, or a 16% increase in shear strength, or at least an 18% increase in shear strength, or at least a 20% increase in shear strength, ' or at least a 22% increase in shear strength, or at least a 24% increase in shear strength, or at least a 25% increase in shear strength, or more, relative to the reference version of the aluminum alloy fastener, wherein the reference version of the aluminum alloy fastener is in one of a T6 temper and a T87 temper.
  • the aluminum alloy body achieves at least equivalent tensile yield strength as compared to a reference-version of the aluminum alloy body in the as-cold worked condition, In one embodiment, the aluminum alloy body achieves at least a 2% increase in tensile yield strength as compared to a reference- ersion of the aluminum alloy body in the as- cold worked condition.
  • the aluminum alloy body achieves at least a 4% increase in tensile yield strength, or at least a 6% increase in tensile yield strength, or at least a 8% increase in tensile yield strength, or at least a 10% increase in tensile yield strength, or at least a 12% increase in tensile yield strength, or at least a 14% increase in tensile yield strength, or at least an 16% increase in tensile yield strength, or more, as compared to a reference-version of the aluminum alloy body in the as-cold worked condition. Similar results may be obtained relative to ultimate tensile strength. These increases may be realized in the L or LT directions.
  • a new HT aluminum alloy body realizes a typical tensile yield strength in the LT direction of at least 35 ksi. In other embodiments, a new HT aluminum alloy body realizes a typical tensile yield strength in the LT direction of at least 40 ksi, or at least 45 ksi, or at least 50 ksi, or at least 51 ksi, or at least 52 ksi, or at least 53 ksi, or at least 54 ksi, or at least 55 ksi, or at least 56 ksi, or at least 57 ksi, or at least 58 ksi, or at least 59 ksi, or at least 60 ksi, or at least 61 ksi, or at least 62 ksi, or at least 63 ksi, or at least 64 ksi, or at least 65 ksi, or at least 66 ksi, or at least 67 k
  • a new HT aluminum alloy body realizes a typical ultimate tensile strength in the LT direction of at least 40 ksi. In other embodiments, a new HT aluminum alloy body realizes a typical ultimate tensile strength in the LT direction of at least 45 ksi, or at least 50 ksi, 51 ksi, or at least 52 ksi, or at least 53 ksi, or at least 54 ksi, or at least 55 ksi, or at least 56 ksi, or at least 57 ksi, or at least 58 ksi, or at least 59 ksi, or at least 60 ksi, or at least 61 ksi, or at least 62 ksi, or at least 63 ksi, or at least 64 ksi, or at least 65 ksi, or at least 66 ksi, or at least 67 ksi, or at least 68
  • the new HT aluminum alloy bodies may achieve a high strength and in a short time period relative to a reference-version of the HT aluminum alloy body in the T6 temper.
  • a new HT aluminum alloy body realizes its peak strength at least 10% faster than a reference- version of the aluminum alloy body in the T6 temper. As an example of 10% faster processing, if the T6-version of the HT aluminum alloy body realizes its peak strength in 35 hours of processing, the new HT aluminum alloy body would realize its peak strength in 31.5 hours or less.
  • the new HT aluminum alloy body realizes it peak strength at least 20% faster, or at least 25% faster, or at least 30% faster, or at least 35% faster, or at least 40% faster, or at least 45% faster, or at least 50% faster, or at least 55% faster, or at least 60% faster, or at least 65% faster, or at least 70% faster, or at least 75% faster, or at least 80% faster, or at least 85% faster, or at least 90% faster, or more, as compared to a reference- version of the HT aluminum alloy body in the T6 temper.
  • a new HT aluminum alloy body realizes its peak strength in less than 10 hours of thermal treatment time. In other embodiments, a new HT aluminum alloy body realizes its peak strength in less than 9 hours, or less than 8 hours, or less than 7 hours, or less than 6 hours, or less than 5 hours, or less than 4 hours, or less than 3 hours, or less than 2 hours, or less than 1 hour, or less than 50 minutes, or less than 40 minutes, or less than 30 minutes, or less than 20 minutes, or less than 15 minutes, or less than 10 minutes of thermal treatment time, or less. Due to the short thermal treatment times, it is possible that paint baiting cycles or coating cures could be used to thermally treat the new HT aluminum alloy bodies,
  • the aluminum alloy body may realize good ductility and in combination with the above-described strengths.
  • the aluminum alloy body achieves an elongation (L and/or LT) of more than 4%.
  • the aluminum alloy body achieves an elongation (L and/or LT) of at least 5%.
  • the aluminum alloy body may achieve an elongation (L and/or LT) of at least 6%, or at least 7%, or at least 8%, or at least 9%, or at least 10%, or at least 1 1%, or at least 12%, or at least 13%, or at least 14%, or at least 15%, or at least 16%, or more.
  • the new HT aluminum alloy bodies may realize good fracture toughness properties, Toughness properties are generally measured in accordance with ASTM E399 and ASTM B645 for plane-strain fracture toughness (e.g., Kic and KQ) and in accordance with ASTM E561 and B646 for plane-stress fracture toughness (e.g., app and KR25).
  • the new HT aluminum alloy body realizes a toughness decrease of not greater than 10% relative to a reference-version of the aluminum alloy body in the T6 temper. In other embodiments, the new HT aluminum alloy body realizes a toughness decrease of not greater than 9%, or not greater than 8%, or not greater than 7%, or not greater than 6%, or not greater than 5%, or not greater than 4%, or not greater than 3%, or not greater than 2%, or not greater than 1% relative to a reference-version of the HT aluminum alloy body in the T6 temper, In one embodiment, the new HT aluminum alloy body realizes a toughness at least equivalent to that of a reference- version of the HT aluminum alloy body in the T6 temper. iv. Stress Corrosion Cracking
  • the new HT aluminum alloy bodies may realize good stress corrosion cracking resistance.
  • Stress corrosion cracking (SCC) resistance is generally measured in accordance with ASTM G47.
  • a new HT aluminum alloy body may achieve a good, strength and/or toughness, and with good SCC corrosion resistance.
  • a new HT aluminum alloy body realizes a Level 1 corrosion resistance.
  • a new HT aluminum alloy body realizes a Level 2 corrosion resistance.
  • a new HT aluminum alloy body realizes a Level 3 corrosion resistance.
  • a new HT aluminum alloy body realizes a Level 4 corrosion resistance.
  • the new HT aluminum alloy bodies may be exfoliation resistant. Exfoliation resistance is generally measured in accordance with ASTM G34. In one embodiment, an aluminum alloy body realizes an EXCO rating of EB or better. In another embodiment, an aluminum alloy body realizes an EXCO rating of EA or better. In yet another embodiment, an aluminum alloy body realizes an EXCO rating of P, or better.
  • Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize improved appearance.
  • the below appearance standards may be measured with a Hunterlab Dorigon II (Hunter Associates Laboratory INC, Reston, VA), or comparable instrument.
  • Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize at least 5% higher specular reflectance as compared to the referenced aluminum alloy body in the T6 temper, In one embodiment, the new aluminum alloy bodies realize at least 6% higher specular reflectance as compared to the referenced aluminum alloy body in the T6 temper. In other embodiments, the new aluminum, alloy bodies realize at least 7% higher specular reflectance, or at least 8% higher specular reflectance, or at least 9% higher specular reflectance, or at least 10% higher specular reflectance, or at least 11% higher specular reflectance, or at least 12% higher specular reflectance, or at least 13% higher specular reflectance, or more, as compared to the referenced aluminum alloy body in the T6 temper,
  • Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize at least 10% higher 2 degree diffuseness as compared to the referenced aluminum alloy body in the T6 temper.
  • the new aluminum alloy bodies realize at least 12% higher 2 degree diffuseness as compared to the referenced aluminum alloy body in the T6 temper.
  • the new aluminum alloy bodies realize at least 14%o higher 2 degree diffuseness, or at least 16% higher 2 degree -diffuseness, or at least 18% higher 2 degree diffuseness, or at least 20% higher 2 degree diffuseness, or at least 22% higher 2 degree diffuseness , or more, as compared to the referenced aluminum alloy body in the T6 temper.
  • Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize at least 15% higher 2 image clarity as compared to the referenced aluminum alloy body in the T6 temper. In one embodiment, the new aluminum alloy bodies realize at least 18% higher 2 image clarity as compared to the referenced aluminum alloy body in the T6 temper. In other embodiments, the new aluminum alloy bodies realize at least 21% higher 2 image clarity, or at least 24% higher 2 image clarity, or at least 27% higher 2 image clarity, or at least 30%) higher 2 image clarity, or more, as compared to the referenced aluminum alloy body in the T6 temper,
  • Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize improved gloss properties.
  • an intended viewing surface of an aluminum alloy body processed in accordance with the new processes disclosed realizes at least an equivalent 60° gloss value as compared to the intended viewing surface of a reference version of the aluminum alloy body in the T6 temper.
  • the new aluminum alloy bodies realize at least a 2% higher 60° gloss value as compared to the intended viewing surface of a reference version of the aluminum alloy body in the T6 temper.
  • an intended viewing surface of the new aluminum alloy body realizes at a 4% higher 60° gloss value, or at least a 6% higher 60° gloss value, or at least an 8% higher 60° gloss value, or more, as compared to the intended viewing surface of a reference version of the aluminum alloy body in the T6 temper.
  • a "60° gloss value” and the like means the 60° gloss value obtained from measuring the intended viewing surface of the aluminum alloy body using 60° angle of gloss and a BYK Gardner haze-gloss Reflectometer (or comparable gloss meter) operated according to manufacturer recommended standards.
  • Aluminum alloy bodies processed in accordance with the new processes disclosed herein may have low surface roughness (e.g., low or no Ludering, low or no orange peel, among others).
  • an aluminum alloy body realizes a surface roughness (Ra) of not greater than 100 micro-inch (Ra) as measured in the LT direction.
  • the aluminum alloy body realizes a surface roughness (Ra) of not greater than 90 micro-inch (Ra) as measured in the LT direction.
  • the aluminum alloy body realizes a surface roughness (Ra) of not greater than.80 micro-inch (Ra) as measured in the LT direction.
  • the aluminum alloy body realizes a surface roughness (Ra) of not greater than 70 micro-inch (Ra) as measured in the LT direction. In yet another embodiment, the aluminum alloy body realizes a surface roughness (Ra) of not greater than 60 micro-inch (Ra) as measured in the LT direction. In another embodiment, the aluminum alloy body realizes a surface roughness (Ra) of not greater than 50 micro-inch (Ra) as measured in the LT direction, or less.
  • surface roughness is to be measured on a specimen that has been pulled to fracture via a tensile test conducted in accordance with ASTM E8 and B557.
  • a product made by the new processes described herein is used in an aerospace application, such as wing skins (upper and lower) or stringers / stiffeners, fuselage skin or stringers, ribs, frames, spars, seat tracks, bulkheads, circumferential frames, empennage (such as horizontal and vertical stabilizers), floor beams, seat tracks, doors, and control surface components (e.g., rudders, ailerons) among others.
  • wing skins upper and lower
  • stringers / stiffeners fuselage skin or stringers
  • ribs frames
  • spars spars
  • seat tracks bulkheads
  • circumferential frames such as horizontal and vertical stabilizers
  • empennage such as horizontal and vertical stabilizers
  • floor beams seat tracks
  • doors and control surface components
  • control surface components e.g., rudders, ailerons
  • a product made by the new processes described herein is used in a munitions / ballistics / military application, such as in ammunition cartridges and armor, among others.
  • Ammunition cartridges may include those used in small arms and cannons or for artillery or tank rounds.
  • Other possible ammunition components would include sabots and fins.
  • Artillery, fuse components are another possible application as are fins and control surfaces for precision guided bombs and missiles.
  • Armor components could include armor plates or structural components for military vehicles. In such applications, the products could offer weight savings or improved reliability or accuracy.
  • a product made by the new processes described herein is used in a fastener application, such as bolts, rivets, screws, studs, inserts, nuts, and lock-bolts, which may be used in the industrial engineering and/or aerospace industries, among others.
  • a fastener application such as bolts, rivets, screws, studs, inserts, nuts, and lock-bolts, which may be used in the industrial engineering and/or aerospace industries, among others.
  • the products could be used in place of other heavier materials, like titanium alloys or steels, for weight reduction. In other cases, the products could provide superior durability.
  • a product made by the new processes described herein is used in an automotive application, such as closure panels (e.g., hoods, fenders, doors, roofs, and trunk lids, among others), wheels, and critical strength applications, such as in body-in-white (e.g., pillars, reinforcements) applications, or any other automotive component that can be produced from the aluminum alloy products described herein.
  • closure panels e.g., hoods, fenders, doors, roofs, and trunk lids, among others
  • critical strength applications such as in body-in-white (e.g., pillars, reinforcements) applications, or any other automotive component that can be produced from the aluminum alloy products described herein.
  • body-in-white applications e.g., pillars, reinforcements
  • a product made by the new processes described herein is used in a marine application, such as for ships and boats (e.g., hulls, decks, masts, and superstructures, among others).
  • the products could be used to enable down-gauging and weight reductions.
  • the products could be used to replace products with inferior corrosion resistance resulting in enhanced reliability and lifetimes.
  • a product made by the new processes described herein is used in a rail application, such as for hopper tank and box cars, among others.
  • the products could be used for the hoppers and tanks themselves or for the supporting structures.
  • the products could provide weight reductions (through down-gauging) or enhanced compatibility with the products being transported.
  • a product made by the new processes described herein is used in a ground transportation application, such as for truck tractors, box trailers, flatbed trailers, buses, package vans, recreational vehicles (RVs), all-terrain vehicles (ATVs), and the like.
  • a ground transportation application such as for truck tractors, box trailers, flatbed trailers, buses, package vans, recreational vehicles (RVs), all-terrain vehicles (ATVs), and the like.
  • RVs recreational vehicles
  • ATVs all-terrain vehicles
  • the products could be used for closure panels or frames, bumpers or fuel tanks allowing down-gauging and reduced weight.
  • the bodies could also be used in wheels to provided enhanced durability or weight savings or improved appearance.
  • a product made by the new processes described herein is used in an oil and gas application, such as for risers, auxiliary lines, drill pipe, choke-and-kill lines, production piping, and fall pipe, among others.
  • the product could allow reduced wall thicknesses and lower weight.
  • Other uses could include replacing alternate materials to improve corrosion performance or replacing alternat materials to improve compatibility with drilling or production fluids.
  • the products could also be used for auxiliary equipment employed in exploration like habitation modules and helipads, among others.
  • a product made by the new processes described herein is used in a packaging application, such as for lids and tabs, food cans, bottles, trays, and caps, among others.
  • benefits could include the opportunity for down-gauging and reduced package weight or cost.
  • the product would have enhanced compatibility with the package contents or improved corrosion resistance.
  • a product made by the new processes described herein is used in a reflector, such as for lighting, mirrors, and concentrated solar power, among others.
  • a reflector such as for lighting, mirrors, and concentrated solar power, among others.
  • the products could provide better reflective qualities in the bare, coated or anodized condition at a given strength level.
  • a product made by the new processes described herein is used in an architecture application, such as for building panels / facades, entrances, framing systems, and curtain wall systems, among others.
  • the product could provide superior appearance or durability or reduced weight associated with down-gauging.
  • a product made by the new processes described herein is used in an electrical application, such as for connectors, terminals, cables, bus bars, and wires, among others.
  • the product could offer reduced tendency for sag for a given current carrying capability.
  • Connectors made from the product could have enhanced capability to maintain high integrity connections over time.
  • the product could provide improved fatigue performance at a given level of current carrying capability.
  • a product made by the new processes described herein is used in a fiber metal laminate application, such as for producing high-strength sheet products used in the laminate, among others which could result in down-gauging and weight reduction.
  • a product made by the new processes described herein is used in an industrial engineering application, such as for tread-plate, tool boxes, bolting decks, bridge decks, and ramps, among others where enhanced properties could allow down-gauging and reduced weight or material usage.
  • a rolled tread product is a product having predetermined pattern of raised buttons on an outer surface of a sheet or plate product.
  • a tread sheet has a thickness of 0.040 inch to 0.249 inch, and a tread plate has a thickness of 0.250 inch to 0,750 inch.
  • the predetermined pattern may be introduced into the rolled tread product during cold rolling of an aluminum alloy body using a roll having a plurality of indentations therein that correspond to the predetermined pattern, wherein the cold rolling achieves at least 25% cold work.
  • Each of the buttons of the predetermined pattern generally has predetermined height, such as a height in the range of 0.197 to 0.984 inch.
  • the rolled tread product is thermally treated (300), and the combination of the cold rolling step (200) and thermally treating step (300) are accomplished such that the rolled tread product realizes improved long-transverse tensile yield strength as compared the tread sheet or tread plate in the as cold worked condition.
  • the rolled tread product realizes at least 5% higher LT tensile yield strength over a referenced rolled tread product, wherein the referenced tread sheet or tread plate has the same composition as the rolled tread product, but the referenced rolled tread product is processed to a T6 temper (i.e., cold rolled to final gauge, then solutionized, and then aged to within 1 ksi of its peak tensile yield strength), such as any of the LT yield strength percentage improvements described in the Properties section (Section H(i)), above, relative to a reference version in the T6 temper.
  • the produced tread product is defect- free as defined by EN 1386: 1996.
  • a product made by the new processes described herein is used in a fluid container (tank), such as for rings, domes, and barrels, among others.
  • a fluid container such as for rings, domes, and barrels, among others.
  • the tanks could be used for static storage. In others, the tanks could be parts of launch vehicles or aircraft. Benefits in these applications couid include down-gauging or enhanced compatibility with the products to be contained.
  • a product made by the new processes described herein is used in consumer product applications, such as laptops, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwaves, cookware, washer/dryer, refrigerators, sporting goods, or any other consumer electronic products requiring durability or desirable appearance.
  • a product made by the new processes described herein is used in a medical device, security systems, and office supplies, among others.
  • the new process is applied to a cold hole expansion process, such as for treating holes to improve fatigue resistance, among others, which may result in a cold work gradient and tailored properties, as described above.
  • This cold hole expansion process may be applicable to forged wheels and aircraft structures, among others.
  • the new process is applied to cold indirect extrusion processes, such as for producing cans, bottles, aerosol cans, and gas cylinders, among others. In these cases the product could provide higher strength which could provide reduced material usage. In other cases, improved compatibility with the contents could result in greater shelf life.
  • a product made by the new processes described herein is used in a heat-exchanger application, such as for tubing and fins, among others where higher strength can be translated into reduced material usage. Improved durability and longer life could also be realized.
  • the new process is applied to a conforming processes, such as for producing heat-exchanger components, e.g., tubing where higher strength can be translated into reduced material usage. Improved durability and longer life could also be realized.
  • a conforming processes such as for producing heat-exchanger components, e.g., tubing where higher strength can be translated into reduced material usage. Improved durability and longer life could also be realized.
  • the new methods disclosed herein may result in improved aluminum ammunition cartridges (also called cases or casings).
  • An aluminum alloy body (2r-l) such as a sheet, plate or extruded rod or bar, may used as a starting material. This material may then be extruded or drawn into member 2r-2 having a base with an intermediate thickness Tl .
  • T2 a final thickness of T2 (e.g., via cold heading, cold forging, cold flow forming, and the like), wherein is T2 chosen so as to induce at least 25% cold work in the base due to the cold forming operation (2r-3).
  • T2 is chosen so as to induce at least 35% cold work in the base, such as at least 50% cold work in the base, or more, due to the cold forming operation.
  • the amount of cold working may be any of the cold working amounts described in the Cold Work section (Section B), above.
  • such cartridges may have a strong base, which may be useful, for example, to restrict distortion in the firing process, and/or facilitate cartridge extraction.
  • Aluminum alloy cartridges produced via these methods may have a uniform sidewall (2r-3 and 2r-4), such as for shotgun casings and large ' diameter casings, such as 50-150 mm casings, and the like, among others.
  • the sidewall is also produced with a high amount of cold work, such as by drawing, ironing, or flow forming, among others.
  • the sidewall and the base may receive cold work at the same time (e.g., via flow forming), or the base and sidewall may receive cold work in separate steps via separate cold working operations.
  • aluminum alloy cartridges produced with the new processes disclosed herein may realize improved properties in the base, the sidewall, or both, such as any of the improved properties described in the Properties section (Section H), above.
  • the aluminum alloy body (2r-l) may be solutionized, or solutionized and partially cold worked, prior to being formed into the ammunition cartridge.
  • Aluminum alloy cartridges produced via the method of FIG. 2r may have a neck portion (2r-5). This neck portion may be produced after the cold working step by conventional operations, Local softening at the neck may be required to facilitate projectile insertion and crimping to secure projectile in position.
  • a method comprises receiving an aluminum alloy armor product, body or component, and attaching the aluminum alloy armor product, body or component as an armor component of an assembly.
  • the as-received aluminum alloy armor product, body or component may have been prepared by the methods described herein, i.e., by solutionizing, then cold working and then thermally treating, such as via any of the methods described in Sections (A) - (C), above.
  • the assembly is a vehicle.
  • the vehicle is a military vehicle
  • the vehicle is a commercial vehicle, such as an automotive vehicle, van, bus, tractor trailer, and the like.
  • the assembly is a body armor assembly.
  • An armor component is a component that is designed for use in an assembly, and with the main purpose of stopping one or more projectiles, such as armor piercing projectiles, blasts, and/or fragments. Armor components are usually used in applications where such projectiles could injure one or more persons, if not stopped.
  • an aluminum alloy armor component has at least 1% higher V50 ballistics limit as compared to a reference version of the aluminum alloy armor component in the T6 temper, wherein the V50 ballistics limits is tested in accordance with MIL-STD-662F(1997) (the impact velocity with a 50% probability for perforation for a given alloy and ).
  • the V50 ballistics limit may be for either armor piercing projectiles (AP) and/or fragment simulating projectiles (FSP).
  • the V50 ballistics limit is armor piercing resistance
  • the aluminum alloy armor component has at least 5% highe V50 AP resistance as compared to a reference version of the aluminum alloy armor component in the T6 temper
  • the aluminum alloy armor component has at least 6% higher, or at least 7% higher, or at least 8% higher, or at least 9% higher, or at least 10% higher V50 AP resistance, or more, as compared to a reference version of the aluminum alloy armor component in the T6 temper.
  • this V50 ballistics limit is fragment simulating projectile resistance
  • the aluminum alloy product has at least 2% higher V50 FSP resistance as compared to a reference version of the aluminum alloy armor component in the T6 temper
  • the aluminum alloy armor component has at least 3% higher, or at least 4% higher, or at least 5% higher V50 FSP resistance, or more, as compared to a reference version of the aluminum alloy product in the T6 temper.
  • a new aluminum alloy armor component has a thickness of from 0.025 inch to 4.0 inch and realizes at least 5% higher V50 armor piercing resistance as compared to a reference version of the aluminum alloy armor component in the T6 temper.
  • the aluminum alloy armor component comprises a predominately unrecrystallized microstructure.
  • the armor component is a plate or forging having a thickness in the range of from 0.250 inch to 4,0 inch.
  • the armor component is a plate or forging having a thickness in the range of from 1.0 inch to 2.5 inch.
  • the armor component is a sheet having a thickness of 0.025 to 0.249 inch (e.g., for body armor).
  • a method comprises cold working a solutionized aluminum alloy body and then thermally treating the aluminum alloy body.
  • the method may comprise forming the aluminum alloy into a predetermined shaped product in the form of an outer component for a consumer electronic product.
  • the forming step may be completed before, after or during the thermally treating step (300), such as described in the Thermal Treatment section (Section C, subsection i), and/or the Optional Post-Thermal Treatments section (Section F), above.
  • an "outer component for a consumer electronic product” and the like means a product that is generally visible to a consumer of the consumer electronic product during normal course of use.
  • an outer component may be an outer cover (e.g., facade) of a consumer electronic product, or a stand or other non-facade portion of the consumer electronic product.
  • the outer component may have a thickness of from 0.015 inch to 0.50 inch.
  • the outer component is an outer cover for the consumer electronics product and has a thickness of from 0.015 inch to 0.063 inch.
  • a method comprises receiving a rolled or forged aluminum alloy body, wherein the aluminum alloy body was prepared by solutionizing and then cold working to final gauge, wherein the cold induced at least 25% cold work in the aluminum alloy body, wherein the cold working was one of cold rolling and cold forging, and then forming the rolled aluminum alloy body into an outer component for a consumer electronic product.
  • the method comprises thermally treating the aluminum alloy.
  • the thermally treating step occurs after the receiving step.
  • the thermally treating step occurs concomitant to the forming step.
  • the aluminum alloy body is subjected to a temperature in the range of from at least 150°F to below the recrystaliization temperature of the aluminum alloy body, as per the Thermal Treatment section (Section C), above.
  • the thermally treating step occurs before the receiving step, i.e., the aluminum alloy body was at least partially thermally treated upon receipt,
  • the forming step is completed at less than 1 0°F. In one embodiment, the forming step is completed at ambient conditions.
  • the forming step may include applying strain to at least a portion of the aluminum alloy body to achieve the outer component, wherein the maximum amount of the strain of the applying step is equivalent to at least 0.01 equivalent plastic strain, such as any of the forming equivalent plastic strain values listed in the Optional Post-Thermal Treatments section (Section F), above.
  • the cold working, thermally treating and forming steps should be accomplished such that the outer component comprises a predominately unrecrystallized microstructure,
  • the new methods described herein may be useful in producing a variety of outer components for consumer electronic products, including any of the consumer electronic products listed above.
  • the consumer electronic product is one of a laptop computer, mobile phone, camera, mobile music player, handheld device,' desktop computer, television, microwave, washer, dryer, a refrigerator, and combinations thereof.
  • the consumer electronic product is one of a laptop computer, a mobile phone, a mobile music player, and combinations thereof, and the outer component is an outer cover having a thickness of from 0.015 to 0.063 inch,
  • the new methods described herein may produce outer components having improved properties.
  • the outer component realizes at least 5% higher normalized dent resistance as compared to a reference version of the aluminum alloy outer component in the T6 temper
  • "Normalized dent resistance” means the dent resistance of an aluminum alloy body as normalized by dividing the inverse of the dent amount (DA) by the thickness of the aluminum alloy body (i.e., (l/DA)/thickness. For example, if a dent amount was. 0.0250 inch and the product had a thickness of 0.0325 inch, its normalized dent resistance would be 94.67 per inch 2 .
  • Dent amount means the dent size of the dent produced by the dent test procedure, described below.
  • the outer component of a consumer electronic product made from a new aluminum alloy processed according to the new methods described herein realizes at least 10% higher, or at least 15% higher, or at least 20% higher, or at least 25% higher, or at least 30% higher, or more, normalized dent resistance than a reference version of the outer component in the T6 temper.
  • an outer component of a consumer electronic product made from a new aluminum alloy processed according to the new methods described herein realizes at least 5% higher normalized dent resistance than the same outer component made from alloy 6061 processed to the T6 temper. In other embodiments, the outer component of a consumer electronic product made from a new aluminum alloy processed according to the new methods described herein realizes at least 10% higher, or at least 15% higher, or more, normalized dent resistance than the same outer component made from alloy 6061 processed to the T6 temper.
  • an outer component of a consumer electronic product made from a new aluminum alloy processed according to the new methods described herein realizes at least 10% higher normalized dent resistance than the same outer component made from alloy 5052 processed to the H32 temper. In other embodiments, the outer component of a consumer electronic product made from a new aluminum alloy processed according to the new methods described herein realizes at least 30% higher, or at least 50% higher, or more, normalized dent resistance than the same outer component made from alloy 5052 processed to the H32 temper,
  • the outer component may have an intended viewing surface, and this intended viewing surface may be free of visually apparent surface defects.
  • "Intended viewing surface” and the like means surfaces that are intended to be viewed by a consumer during normal use of the product.
  • Internal surfaces e.g., the inside of an outer cover
  • Internal surfaces are generally not intended to be viewed during normal use of the product.
  • internal surfaces of a mobile electronic device cover are not normally viewed during normal use of the product (e.g., when using to send text messages and/or when using to converse telephonically), but such internal surfaces may be occasionally viewed during non-normal usage, such as when changing the battery, and, thus, such internal surfaces are not intended viewing surfaces.
  • Free of visually apparent surface defects means that the intended viewing surface of the cover is substantially free of surface defects as viewed by human eyesight, with 20/20 vision, when the cover is located at least 18 inches away from the eyes of the human viewing the cover.
  • visually apparent surface defects include those cosmetic defects that can be viewed due to the forming process and/or the alloy microstructure, among others.
  • the presence of visually apparent surface defects is generally determined after anodizing (e.g., immediately after anodizing, or after application of a coating or other dye / colorant, for instance).
  • the outer component realizes maintained or improved appearance properties, such as any of the appearance properties listed in the Properties section (Section H) thread above.
  • the intended viewing surface of the outer component realizes at least an equivalent 60° gloss value as compared to an intended viewing surface of the reference version reference version of the aluminum alloy outer component in the T6 temper.
  • a "60° gloss value” and the like means the 60° gloss value obtained from measuring the intended viewing surface of the aluminum alloy body using 60° angle of gloss and a BY Gardner haze-gloss Reflectometer (or comparable gloss meter) operated according to manufacturer recommended standards.
  • the new methods disclosed herein may also be useful in producing new aluminum alloy containers having improved properties.
  • One method of producing a container is illustrated in FIG. 2s-l , and includes cold working a solutionized aluminum alloy body into a container (200-C) and then thermally treating the container (300-C), optionally with final treatments (400- C). Examples of cold working steps (200-C), thermal treatment steps (300-C) and optional final treatment(s) (400-C) that may be employed to achieve the new aluminum alloy containers are described in further detail below.
  • top, bottom, “below”, “above”, “under”, “over”, etc, are relative to the position of a finished aluminum alloy container resting on a flat surface, regardless of the orientation of the aluminum alloy container during cold working or forming processes.
  • the top of the container has an opening.
  • a “container” is any type of container that may be made from an aluminum alloy, including but not limited to, beverage cans, bottles, food cans, aerosol cans, one- piece cans, two-piece cans and three-piece cans.
  • a “finished aluminum alloy container” is an aluminum alloy container that will not undergo additional cold working or forming steps before it is used by an end consumer
  • ironing means stretching and thinning the walls of a cup via a punch pushing the sidewall of the cup against ironing rings.
  • Doming means producing the base of the container, the base of the container may be shaped like a dome, may be flat, or may have an alternate geometry,
  • Beading means producing a circumferential bead on the sidewall of the
  • “Seaming” is a method of attaching a lid to the container, such as mechanically bonding and the like.
  • “Curling” means producing a top edge of the container to accept a closure, such as a lid, an end, lug, threaded closure, a crown, a roll-on pilfer proof closure, etc.
  • a reference version of the container in the as cold worked condition means a version of the aluminum alloy container that is prepared identically to the claimed container, but whose mechanical properties are tested after completion of the cold working step and prior to the thermal treatment step, Preferably, the mechanical properties of the reference version of the container in the as-formed condition are measured within 4 - 14 days of completion of the cold working step.
  • a reference version of the container in the as-cold worked condition one would cold work the aluminum alloy body into a container according to the practices described herein, after which a portion of the aluminum alloy container is removed to determine its properties in the as' cold worked condition per the requirements described above, Another portion of the aluminum alloy container would be thermally treated in accordance with the new processes described herein, after which its properties would be measured, thus facilitating a comparison between the properties of a reference version of the container in the as cold worked condition and the properties of a container processed in accordance with the new processes described herein (e.g., to compare dome reversal pressure, vacuum strength, strength, and/or elongation, among others). Since the both the new container and the reference version of container in the as cold worked condition are produced from the same aluminum alloy container, they would have the same composition. Thus, a reference- version of the container is comprised of the same alloy, gauge and geometry as the new container.
  • Dome reversal pressure means the threshold pressure above which the base of the can 'pops out' and becomes convex instead of concave.
  • the aluminum alloy may be sufficiently strong to enable the base of the container to be flat instead of concave.
  • the dome reversal pressure means the threshold pressure above which the base of the can 'pops out' and becomes convex instead of flat. Dome reversal pressure may be measured using an Altek Company beverage can and lid tester Model 9009C5
  • a “sidewall” is a wall of the side of the container.
  • a "a sidewall of a reference-version of the container in the T6 temper” and the like means a sidewall of a container that has been solutionized and then thermally treated to a maximum strength condition (within 1 ksi of peak strength).
  • a sidewall of a reference-version of the container in the T6 temper and the like means a sidewall of a container that has been solutionized and then thermally treated to a maximum strength condition (within 1 ksi of peak strength).
  • a sidewall of a reference-version of the container in a T6 temper one would obtain a sidewall of an aluminum alloy container, after which a portion of the sidewall would be processed to a T6 temper (i.e., solutionized and then thermally treated to a maximum strength condition, within 1 ksi of peak strength).
  • Another portion of the sidewall would be processed (or may have already been processed) in accordance with the new processes described herein, thus facilitating a comparison between the properties of the sidewall of the reference-version of the aluminum alloy container in the T6 temper and the properties of an aluminum alloy container processed in accordance with the new processes described herein (e.g., to compare dome reversal pressure, vacuum strength, strength, and/or elongation, among others). Since both sidewalls are obtained from the same aluminum alloy container, they would have the same composition, gauge and geometry,
  • Vacuum strength may be measured by an Altek Company food Panel Strength (sidewall collapse resistance) tester - Model 9025.
  • the new aluminum alloy containers may be prepared by cold working (200-C) and then thermally treating (300-C).
  • an aluminum alloy body such as a sheet or a slug, is cold worked at least 25% (e.g., by one or more of drawing, ironing and impact extruding), and this cold working step induces at least 25% cold work into at least a portion of the container, such as by any of the cold work amounts disclosed in the Cold Working section (Section B), above.
  • the at least 25% cold work is induced in a part of (or the whole of) the sidewall.
  • the at least 25% cold work is induced in a part of (or the whole of) the base.
  • the cold working step (200-C) comprises cold working at least a potion of the aluminum alloy body into a container. In some embodiments, the cold working step (200-C) comprises cold working at least a portion of the aluminum alloy body into a container, and the cold working induces at least 35% cold work, or at least 50% cold work, or at least 75% cold work, or more, into at least a portion of the container. In one embodiment, the cold working operation is initiated at a temperature of less than l 50°F.
  • the aluminum alloy body is in sheet form prior to the cold working.
  • the aluminum alloy sheet can be of ' a thickness appropriate for the container.
  • the gauge of the container may be reduced as compared to a prior art container having the same geometry, while the minimum performance requirements of the container may be maintained. This ability to down-gauge may result in reduced container weight and cost.
  • the sheet may have a thickness of less than 0,0108 inch, or less than 0.0100 inch, or less than 0.0098 inch, or less than 0.0095 inch or less than 0,0094 inch or less than 0.0605 inch.
  • the sheet may have a thickness of less than 0.0084 inch, or less than 0.0080 inch, or less than 0.0076 inch, or less than 0.0074 inch.
  • the sheet may have a thickness of less than 0,008 inch.
  • the aluminum alloy sheet is pre-coated, i.e., the aluminum alloy sheet is coated with a coating before the cold working step (200-C).
  • the container may be thermally treated (300-C).
  • the thermally treating step (300-C) may be accomplished as per the Thermal Treatment section (Section C), above.
  • the thermally treating step (300-C) comprises heating the aluminum alloy container in the range of from 150°F to below the recrystallization temperature of the aluminum alloy body.
  • the thermally treating step (300- C) is completed at a temperature of from 150°F to 600°.
  • the thermally treating step (300-C) is completed at a temperature of not greater than 550°F, such as not greater than 500°F > or not greater than 450°F, or not greater than 425°F.
  • the cold working step (200-C) and the thermally treating step (300-C) are performed such that the aluminum alloy container retains or realizes a predominately unrecrystallized microstructure (defined in the Microstructure section (Section E), above).
  • a predominately unrecrystallized microstructure defined in the Microstructure section (Section E), above.
  • the as-received aluminum alloy body may have a predominantly unrecrystallized microstructure, such as when the as-received aluminum alloy sheet was post-solutionized cold rolled by at least 25%.
  • the cold working step (200-C) and thermally treating step (300-C) may be accomplished to realize or retain a predominantly unrecrystallized microstructure (although the microstructure of the container and body may be different, they have a predominantly unrecrystallized microstructure, per the definition of Section E).
  • a predominantly unrecrystallized microstructure although the microstructure of the container and body may be different, they have a predominantly unrecrystallized microstructure, per the definition of Section E).
  • the thermally treating step (300-C) may include steps that already occur in standard container malting processes, such as inserting the container into an oven (320- C),
  • the thermally treating step (300-C) may include inserting the container into an oven (or other heating apparatus) (320- C) so as to, for example, dry the container after washing, cure a coating that was applied to the inside of the container and/or to dry paint applied to the outside of the container,
  • the optional final treatment(s) step (400-C) may be used to produce the container.
  • at least some of the optional final treatments (400) may occur after the thermal treatment step (300-C).
  • some final treatments (400-C) occur before or during thermal treatment (300-C).
  • paint and/or coatings may be applied after the cold working ste (200-C), after which such paint and/or coatings may be cured.
  • the thermally. treating step (300-C) may be used to cure such paint and/or coatings, and thus at least a portion of the final treatment step (400-C) may occur concomitant to at least a portion of the thermal treatment step (300-C),
  • the paint and/or coatings may be cured at low temperatures so as to avoid initiation of thermal treatment (300-C), and potential hardening of the containers. That is, ovens used to heat the container (or other heating apparatus) may be avoided until the container is in its final form, Since strength may increase upon thermal treatment, avoiding heat may enable the aluminum alloy container to remain relatively soft until after the container has been finally formed (e.g., via necking, flanging, curling, threading and/or beading or otherwise forming into its final shape). For example, and with reference now to FIGS, 2s-4 and 2s- 5, at least some finishing and/or forming operations (400-C) may be performed in advance of the thermal treatment step (300-C).
  • paint and/or coatings may be cured via radiation, such as UV light, and in the absence of purposeful conductive heating and/or convective heating of the container.
  • the curing would not thermally treat (300-C) the container because such radiation step would not materially heat the aluminum alloy body,
  • the cold working a solutionized aluminum alloy sheet into a container step (200-C) may comprise drawing the container (220-C) and optionally, ironing the container (240-C).
  • the container may be painted (410-C), then cured via radiation (420-C), and then necked and/or beaded (430-C), after which it is thermally treated (300-C).
  • the cold working a solutionized aluminum alloy sheet into a container step (200-C) may comprise drawing the container (220-C) and optionally, ironing the container (240-C).
  • the optional final treatment(s) (400-C and/or 400-C) step may include "forming operations" (defined in Section F, above), which may include necking, flanging, beading, curling and/or threading, or otherwise forming the container into its final shape before, during or after the thermally treating step (300-C).
  • the aluminum alloy may become stronger during the container production process, it is possible to start the process with an aluminum alloy body that is softer and more formable. Such aluminum alloy bodies may, therefore, be easier to form into complex shapes and/or may be produced in fewer steps than the same container made by prior art processes.
  • improved properties may be realized, such as one or more of an improvement in column buckling strength, dome reversal pressure and vacuum strength, among others.
  • the new aluminum alloy containers realize improved properties over a reference version of the aluminum alloy container in the as-cold worked condition.
  • the new aluminum alloy containers realize improved properties over a reference version of the aluminum alloy container in the T6 temper.
  • the cold working and the thermally treating steps are accomplished to achieve at least a 5% increase in dome reversal pressure as compared to a reference version of the container in the as-cold worked condition.
  • the cold working and the thermally treating steps are accomplished such that the container has a dome reversal strength of at least 90 lbs/sq. inch,
  • the cold working step induces at least 25% cold work in at least a portion of a sidewall of a container.
  • the cold working and the thermally treating steps may be accomplished to achieve at least a 5% increase in tensile yield strength relative to the portion of the sidewall having the at least 25% cold work as compared to the tensile yield strength of the same sidewall portion of a reference-version of the container in the T6 temper, such as any of the tensile yield strength improvements described in the Properties section (Section H), above.
  • the cold working and the thermally treating steps are accomplished to achieve at least a 5% increase in tensile yield strength relative to the portion of the sidewall having the at least 25% cold work as compared to the tensile yield strength of the same sidewall portion of the container in the as-cold worked condition, such as any of the tensile yield strength improvements described in the Properties section (Section H), above.
  • the cold working and the thermally treating steps are accomplished to achieve at least a 5% improvement in vacuum strength as compared to the container in the as cold- worked condition.
  • the cold working and the thermally treating steps are accomplished such that the container has a vacuum strength of at least 24 psi, at least 28 psi, or at least 30 psi, or more.
  • the sidewall of the container is more puncture resistant than (i) a prior art container of the same gauge and geometry, (ii) a container in the as-cold worked condition, and/or (iii) a reference version of the container in the T6 temper.
  • the formability of the container may be maintained, or even improved.
  • the applicable portion of (or the whole of) the aluminum alloy container may realize an elongation of at least 4%, or at least 5%, or at least 6%, or at least 7%, or at least 8%, or more.
  • the aluminum alloy body may contain sufficient solute to promote at least one of a strain hardening response and a precipitation hardening response to achieve the improved property or properties.
  • the potentially improved strength realized by containers made by the presently disclosed methods may also facilitate production of containers having a fiat base or a larger dome window.
  • the sheet may have been cold worked, for example via cold rolling, prior to cold working into a container, as per the Cold Work section (Section B) and/or the Thermal Treatment section (Section C).
  • the container (800-C) has sidewalls (820-C) and a bottom (840-C), also known as a base or a dome.
  • the aluminum alloy container comprising (800-C) the sidewalls (820-C) and bottom (840-C) may be a single, continuous aluminum alloy sheet.
  • the container is a closure (900-C).
  • the closure is a lid.
  • a "fastener” is a product made from a rolled, extruded, or drawn stock that has the primary purpose of connecting two or more components.
  • Fasteners made according to the new processes described herein may be prepared for post-solutionizing cold work (100), and then cold worked by more than 25% (200) and then thermally treated (300).
  • a cold working step (200) comprises cold working an aluminum alloy body into a fastener by one of cold forging, cold swaging and cold rolling.
  • a first portion of the cold working step produces a fastener feed stock (e.g., cold worked rod (including wire) or bar), and a second portion of the cold working step produces the fastener (e.g., via cold forging or cold swaging).
  • a fastener feed stock e.g., cold worked rod (including wire) or bar
  • a second portion of the cold working step produces the fastener (e.g., via cold forging or cold swaging).
  • a fastener may be one-piece or a multiple-piece system.
  • a one-piece fastener may have a body and a head,
  • a fastening system has at least two components, such as a first piece with a body and a head, and a second piece (locking member) designed to attach to the first piece, such as a nut or collar.
  • Examples of fasteners having a body and a head include rivets, screws, nails, and bolts (e.g., lock bolts).
  • Part of a fastener may have one or more threads.
  • Fasteners have at least 2 primary failure modes, the first being tension where the primary loading direction is parallel to the centerline of the fastener and shear where the primary loads are perpendicular to the centerline of the fasteners.
  • the longitudinal ultimate tensile strength of the body of the fastener is the primary factor in determining its failure load in tension and the shear strength is the primary factor in determining its failure load in shear.
  • a new aluminum alloy fastener realizes a tensile yield strength and/or ultimate tensile strength that is at least 2% higher than a reference version of the aluminum alloy fastener in the as-cold worked condition and/or the T6 condition, such as any of the tensile yield strength and/or ultimate tensile strength values described in the Properties section (Section H(i)) 5 above, In one embodiment, a new aluminum alloy fastener realizes a shear strength that is at least 2% greater than a reference version of the fastener, such as any of the shear strength values described in the Properties section (Section H(i)), above, wherein the reference version of the fastener is in a T6 temper.
  • the improved strength properties may relate to one or more of the pin, head or locking mechanism of the fastener.
  • the improved strength relates to the pin of the fastener.
  • the improved strength relates to the head of the fastener.
  • the improved strength relates to the locking mechanism of the fastener.
  • a new aluminum alloy fastener had a predominately unrecrystallized micro structure, as described in the Microstructure section (Section E(i)), above.
  • a method comprises first cold working an aluminum alloy body into a fastener stock.
  • the method may further comprise second cold working the fastener stock into a fastener.
  • This second cold working step may produce the head, the pin and/or the locking member.
  • a third cold working step may optionally be employed, wherein at least one thread ("threaded portion") is produced in the fastener (e.g., in the pin and/or the locking member),
  • the combination of the first, second and optional third cold working steps may result in the fastener having at least 25% cold work.
  • the aluminum alloy fastener may then be thermally treated, as provided above.
  • the first cold working step induces at least 25% cold work into the fastener stock.
  • the second cold working step induces at least 25% cold work into the fastener.
  • the third cold working step induces at least 25% cold work into the threaded portion.
  • one or more portions of the fastener may have more than 25% cold work, such as any of the cold work amounts described in the Cold Work section (Section B), above, depending on processing.
  • a rod product is a rod or wire product, as defined the Aluminum Association
  • a method comprises preparing an aluminum alloy rod for post-solutionizing cold work, described above, after the preparing step, cold working the aluminum alloy rod to final gauge, wherein the cold working induces at least 25% cold work into the rod, and, after the cold working step, thermally treating the aluminum alloy rod, wherein the cold working and the thermally treating steps are accomplished to achieve an increase in longitudinal ultimate tensile strength as compared to a reference- version of the aluminum alloy rod in the as cold- worked condition and/or the T6 temper and/or the T87 temper, or any other of the improved properties described in the Properties section (Section H), above.
  • the cold working step may comprise of one cold drawing, cold rod rolling and cold swaging.
  • the rod is at wire gauge.
  • a new aluminum alloy rod realizes an ultimate tensile strength that is higher than a reference version of the aluminum alloy rod, wherein the reference version is in one of the T6 temper and the T87 temper, such as any of the ultimate tensile strength values described in the Properties section (Section H), above.
  • a new aluminum alloy rod had a predominately unrecrystallized microstructure, as described in the Microstructure section (Section E(i)) f above.
  • the new methods described herein may also be useful in producing improved wheel products.
  • the illustrated wheel (1 10-W) comprises a disk face (1 12- W), a rim (1 14- W), a drop well (1 16- W), a bead seat (118-W) and a mounting flange (120-W).
  • the rim (112-W) is the outer part of the wheel on which a tire may be mounted.
  • the mounting flange (120-W) is the location of the wheel attached directly to a vehicle (e.g., in contact with).
  • the disk face (1 12-W) is located between the rim and the mounting flange,
  • the wheel shown in FIGS, 2t-l and 2t-2 is an auto wheel.
  • the new methods described herein may be applicable to commercial wheels, or any other type of wheel that may be formed by cold working by at least 25%, Also, those skilled in the art know that wheels may have more or fewer parts.
  • a solutionized aluminum alloy body e.g., a solutionized aluminum alloy feedstock, such as ingot
  • a solutionized aluminum alloy feedstock such as ingot
  • this cold working step may induce at least 25% cold work in at least one of The disk face (112- W), the rim (1 14- W), the drop well (1 16-W), the bead seat (1 18-W) and the mounting flange ( 20-W).
  • the cold working induces at least 25% cold work in the disk face (1 12- W).
  • the cold working induces at least 25% cold work in the rim (114- W). In one embodiment, the cold working induces at least 25% cold work in the drop well (116-W). In one embodiment, the cold working induces at least 25% cold work in bead seat (118-W). In one embodiment, the cold working induces at least 25% cold work in the mounting flange (120-W). Higher levels of cold work may be induced, such as any of the cold working amounts described in the Cold Work section (Section B), above. In one embodiment, the cold working step induces at least 35% cold work in at least a portion of the wheel, which portion may be a part of (or the whole of) any of the above-described wheel parts.
  • the cold working step induces at least.50%» cold work, or at least 75%» cold work, or at least 90% cold work, in at least a portion of the wheel, which portion may be a part of (or the whole of) any of the above- described wheel parts, In yet another embodiment, the cold working step induces at least 90% cold work in at least a portion of the wheel, which portion may be a part of (or the whole of) any of the above-described wheel parts.
  • the cold working step may utilize one or more of the following operations to cold work and produce the wheel: spinning, rolling, burnishing, flow forming, shear forming, pilgering, swaging, radial forging, cogging, forging, extruding, nosing, hydrostatic forming and combinations thereof.
  • the cold working comprises flow forming.
  • the cold working step (200) forms a wheel using one or more forming techniques.
  • the geometric complexity of a desired cold-formed output shape (e.g., a wheel) has two major forming process considerations: (1) the overall shape may be subdivided into sub-regions that can be processed more conveniently; and (2) the deformation character will be one of redundant work and high deformation pressures.
  • the intermediate manufacturing geometry may be subdivided into two regions.
  • the first region is the disk face (also called the wheel face, head or hub region) that extends from the centerline of the geometry to the outer radial portion.
  • Second is the wheel rim region (also called the tube well or skirt region) that is similar to a short thick-walled cylinder,
  • these regions can be regarded as independent regions where independent deformation processes could form the final output shapes of both connected regions.
  • these two regions are separate pieces of a multi-piece wheel design, then independent deformation processes could be used to form each piece before joining.
  • the pieces of the multi-piece wheel could be comprised of different aluminum alloys, with at least one of the alloys being a heat treatable aluminum alloy.
  • the geometric transformation to the desired cold-formed output shape requires the use of forming processes with inherent redundant deformation. These processes impart effective strains that are greater than those computed by considering only initial and final section dimensions. This results in correspondingly higher flow stresses.
  • the materia s post-solutionized cold flow stress is significantly higher than its pre-solutionized cold flow stress counterpart. -
  • imparting the minimum necessary cold work to form the output geometry from the intermediate manufacturing geometry is a significantly greater challenge in terms of equipment loading than any pre-solutionization deformation forming the intermediate manufacturing geometry.
  • Incremental Forming These deformation options are those where the forming load is concentrated in a small local area on the component to achieve high forming pressures that can deform a component.
  • Options to dimension and contour the rim region include: flow forming, shear forming, spinning, rolling, pilgering, swaging, cold forging and radial forging.
  • Options to dimension and contour the face region include: flow forming, spinning, shear forming, radial forging and cogging (radial and/or circumferential).
  • Flow forming is an incremental metal forming technique in which a disk or tube of metal is formed over a mandrel by one or more rollers using pressure, where the roller deforms the workpiece, forcing it against the mandrel, usually both axially lengthening the workpiece while radially thinning the workpiece. Flow forming subjects the workpiece to friction and deformation.
  • Flow forming is often used to manufacture automobile wheels and other axisymetric shaped products and can be used to draw a wheel to net width from a machined blank. During flow forming, the workpiece is cold worked, changing its mechanical properties, so its strength becomes similar to that of forged metal.
  • a wheel is formed incrementally staring with a flat cylinder having a diameter less than that of the rim, but thick enough to be deformed at least 25% to form the final face thickness.
  • the face may be flow formed against the mandrel's face surface to achieve the final disk thickness and contour. This flow forming operation may also displace enough metal outward radially beyond the final rim outer diameter to make the rim,
  • the starting flat cylinder can be formed by cross-rolling a plate to the desired face thickness. The needed rim material could be available by having an appropriately sized larger starting diameter.
  • the skirt may be flow formed into a rim and contoured against a mandrel's rim face.
  • a starting cylinder of solutionized material is forged to form the disk face region and extrude a straight rim.
  • the rim may then be flow formed to the final thickness and contour.
  • Another option is to swage the rim to the final shape.
  • a solutionized thick-walled cylinder may be forged into a blind face cavity, where it turns radially inward by channeled angular indirect extrusion to form the face region.
  • a solutionized preform has: (1) the top side dished so that there is more material on the outer diameter with a minimum height to achieve the minimum cold reduction, and (2) the bottom side with an annular projection about the size of the wheel rim.
  • the preform may then be placed into a hydrostatic chamber with a bottom annular chamber opening corresponding to the preform' s bottom annular projection,
  • the preform' s annular projection may be tapered to match the chamber's bottom annular opening to quickly form a seal under pressure.
  • the chamber may be pressurized so the fluid pushes the top surface causing metal flow to exit the annular opening,
  • the extra material at the outer radial region supplies metal forming the rim while the middle thinner region thins and pushes metal radially outward to convert the top dish shape to a flatter shape while cold working the wheel face region.
  • the wheel may be thermally treated (300), as per the Thermal Treatment .section (Section C), above.
  • the wheel is thermally treated at a temperature of from 150°F to below its recrystallization temperature.
  • the thermally treating step comprises heating the wheel at a temperature of not greater than 425°F, In one embodiment, the thermally treating step comprises heating the wheel at a temperature of not greater than 400T. In one embodiment, the thermally treating step comprises heating the wheel at a temperature of not greater than 375°F. In one embodiment, the thermally treating step comprises heating the wheel at a temperature of not greater than 350°F. In one embodiment, the thermally treating step comprises heating the wheel at a temperature of at least 200°F. In one embodiment, the thermally treating step comprises heating the wheel at a temperature of at least 250°F. In one embodiment, the thermally treating step comprises heating the wheel at a temperature of at least 300°F.
  • the cold working step (200) and the thermally treating step (300) may be accomplished to achieve a wheel having improved properties, as described in the Cold working and thermally-treating combination section (Section D, above).
  • the cold working and thermally treating steps are accomplished to achieve at least a 5% improvement in longitudinal (L) tensile yield strength in the cold worked portion of the wheel as compared to the longitudinal tensile yield strength in the cold worked portion of the wheel in the as-cold worked condition.
  • the cold working and thermally treating steps are accomplished to achieve at least a 10% improvement in longitudinal tensile yield strength, or at least a 15% improvement in longitudinal tensile yield strength, or at least a 16% improvement in longitudinal tensile yield strength, or at least a 17% improvement in longitudinal tensile yield strength, or at least a 18% improvement in longitudinal tensile yield strength, or at least a 19% improvement in longitudinal tensile yield strength, or at least a 20% improvement in longitudinal tensile yield strength, or at least a 21% improvement in longitudinal tensile yield strength, or at least a 22% improvement in longitudinal tensile yield strength, or at least a 23% improvement in longitudinal tensile yield strength, or at least a 24% improvement in longitudinal tensile yield strength, or at least a 25% improvement in longitudinal tensile yield strength, or more, in the cold worked portion of the wheel as compared to the longitudinal tensile yield strength in the cold worked portion of the wheel in the as-cold worked condition.
  • the cold worked portion of the wheel has a longitudinal elongation of at least 4%, such as any of the elongation values described in the Properties section. (Section H), above.
  • the cold worked portion of the wheel may have a longitudinal elongation of at least 6%.
  • the cold worked portion of the wheel realizes an elongation of at least 8%, such as at least 10%, or at least 12%, or at least 14%, or at least 16%, or more.
  • Aluminum alloy wheel products made by the new processes disclosed herein may realize another or alternative improved property or properties in the portion of the wheel having the at least 25%. cold. work.
  • the portion of the wheel having the at least 25% cold work may realize at least at least a 5% higher longitudinal tensile yield strength as compared to the longitudinal tensile yield strength of the same portion of a reference version of the wheel processed to the T6 temper, such as any of the T6 improvements described in the Properties section (Section H), above.
  • the aluminum alloy body may contain sufficient solute to promote at least one of a strain hardening response and a precipitation hardening response to achieve the improved property or properties.
  • the new wheel products may realize a predominately unrecrystallized micro structure in the portion of the wheel receiving the at least 25% cold work, such as any of the microstructures described in the Microstructure section (Section E), above, In some embodiments, the portion of the wheel receiving the at least 25% cold work is at least 75% unrecrystallized.
  • a wheel, or other predetermined shaped product can be an assembly containing at least one component manufactured by the techniques described herein.
  • one component could comprise the rim, drop well and bead seats and another could comprise the disk face and or mounting flange.
  • the assembly could contain different aluminum alloys manufactured using the techniques described herein, with at least one of the aluminum alloys being a heat treatable aluminum alloy.
  • the new HT aluminum alloy products may find use in multi-layer applications. For example it is possible that a multi-layer product may be formed using a new HT aluminum alloy body as a first layer and any of the lxxx-8xxx alloys being used as a second layer.
  • FIG 12 illustrates one embodiment of a method for producing multi-layered products.
  • a multi-layered product may be produced (107), after which it is homogenized (122), hot rolled (1 6), solutionized (140) and then cold rolled (220), as described above relative to FIG. 9.
  • the multi-layered products may be produced via multi-alloy casting, roll bonding, adhesive bonding, welding, and metallurgical bonding, among others.
  • Multi-alloy casting techniques include those described in U.S. Patent Application Publication No. 20030079856 to Kilmer et al., U.S. Patent Application No. 20050011630 to Anderson et al., U.S. Patent Application No, 20080182122 to Chu et al., and WO2007/098583 to Novelis (the so-called FUSIONTM casting process).
  • a first layer may be a new HT aluminum alloy product processed in accordance with the new processes disclosed herein.
  • a second layer may be any of a lxxx-8xxx aluminum alloy product ⁇ including another new HT aluminum alloy product (which may be the same alloy or a different alloy than the new HT aluminum alloy product).
  • the first and second layers may have the same thickness, or may be of different thicknesses,
  • the multi-layer product may realize tailored properties with the first layer realizing a first set of properties, and the second layer realizing a second set of properties. Processing of the at least two different layers to produce a multi-layer product is discussed in further detail below.
  • the second layer comprises non-heat treatable alloy, such as any of the l xx, 3xxx, 4xxx, 5xxx and some 8xxx aluminum alloys.
  • a multi-layer product comprises a first layer of a new HT aluminum alloy product processed in accordance with the new processes disclosed herein, and at least a second layer of a non-heat treatable alloy, i.e., a NEW-NHT product, where the new HT is the first layer and the NHT is the second layer of a non-heat treatable aluminum alloy.
  • the second layer comprises a corrosion resistant type alloy, such as any of the lxxx, 3xxx, 5xxx and some 8xxx aluminum alloys.
  • the first layer may provide improved strength properties
  • the second layer may provide corrosion resistant properties. Since a non-heat treatable alloy is used as the second layer, this second layer may not naturally age, and thus may retain its ductility. Thus, in some instances, the second layer may have higher ductility and/or a different strength than the first layer.
  • a multi-layer product with a tailored ductility differential (or gradient) and/or a tailored strength differential (or gradient) may be produced.
  • the second layer is the outer layer of a multi-layer product, and the second layer's resistance to ductility changes may be useful in hemming operations (e.g., for automotive sheet applications, such as inner and/or outer door panel applications, among others).
  • the second layer is a 5xxx aluminum alloy having at least 3 wt. % Mg.
  • the second layer comprises an aluminum alloy having improved appearance properties as compared to the first aluminum alloy layer, such as when the second layer is a lxxx, 3xxx or a 5xxx aluminum alloy.
  • the second layer comprises a heat treatable alloy, such as any of a 2xxx aluminum alloy, a 6xxx aluminum alloy, a 7xxx aluminum alloy, an Al-Li alloy, some 8xxx aluminum alloys, and another new HT aluminum alloy, which may have the same or different composition that the first new HT aluminum alloy layer, i.e., a NEW-HT product, where the new HT is the first layer and where the HT is the second layer of the heat treatable aluminum alloy. Since the second layer is a heat treatable aluminum alloy, it may be processed according to the new processes disclosed herein and realize improved properties over conventionally processed materials.
  • a heat treatable alloy such as any of a 2xxx aluminum alloy, a 6xxx aluminum alloy, a 7xxx aluminum alloy, an Al-Li alloy, some 8xxx aluminum alloys, and another new HT aluminum alloy, which may have the same or different composition that the first new HT aluminum alloy layer, i.e., a NEW-HT product, where the new HT is the first layer and
  • an Al-Li alloy is any aluminum alloy containing 0.25 - 5.0 wt. % Li. Processing of the at least two different layers to produce a multi-layer product is discussed in further detail below.
  • the multi-layer product is a NEW(1)-NEW(2) product, where NEW(l ) is a first layer of a new HT aluminum alloy product produced according 1 to the processes disclosed herein, and NEW(2) is a second first layer of a new HT aluminum alloy product, which second layer may be conventionally processed or may be produced according to the processes disclosed herein.
  • the first and second layers have at least one compositional difference or at least one processing difference.
  • NEW(l) has a different composition than NEW(2).
  • NEW(l) receives a different amount of cold work relative to NEW(2).
  • NEW(l) receives a different thermal treatment practice relative to NEW(2).
  • the NEW(2) layer comprises low- Cu to promote good corrosion resistance (e.g., less than 0.25 wt. % Cu), and the NEW(l)layer comprises more Cu (e.g., at least 0.25 wt. % Cu) having improved strength relative to the NE (l) alloy.
  • the NEW(l ) layer may comprise low Si, low Mg and/or low Cu, such as for improved formability applications (e.g., hemming of automotive components).
  • the first and second new HT layers are selected such that they do not impact recyclability (e.g., for scrap stream purposes).
  • a multi-layer product is a NEW-7xxx product, where the NEW is a- first layer of a new HT aluminum alloy product produced according to the processes disclosed herein, and the 7xxx is a second layer of a 7xxx aluminum alloy product, which may or may not be produced in accordance with the processes disclosed herein,
  • Such multi-layer products may find applicability in automotive, aerospace and armor applications, among others.
  • a multi-layer product is a NEW-2xxx product, where the NEW is a first layer of a new HT aluminum alloy product produced according to the processes disclosed herein, and the 2xxx is a second layer of a 2xxx aluminum alloy product, which may or may not be produced in accordance with the processes disclosed herein,
  • Such multi-layer products may find applicability in automotive, aerospace and armor applications, among others.
  • a multi-layer product is a NEW-Al-Li product, where the NEW is a first layer of a new HT aluminum alloy product produced according to the processes disclosed herein, and the Al-Li is a second layer of a Al-Li aluminum alloy product, which may or may not be produced in accordance with the processes disclosed herein.
  • the NEW is a first layer of a new HT aluminum alloy product produced according to the processes disclosed herein
  • the Al-Li is a second layer of a Al-Li aluminum alloy product, which may or may not be produced in accordance with the processes disclosed herein.
  • Such multi-layer products may find applicability in automotive, aerospace and armor applications, among others,
  • a multi-layer product is a NEW-6xxx product, where the NEW is a first layer of a new HT aluminum alloy product produced according to the processes disclosed herein, and the 6xxx is a second layer of a 6xxx aluminum alloy product, which may or may not be produced in accordance with the processes disclosed herein,
  • Such multi-layer products may find applicability in packaging, automotive, aerospace and armor applications, among others.
  • a multi-layer product is a NEW-8xxx(HT) product, where the NEW is a first layer of a new HT aluminum alloy product produced according to the processes disclosed herein, and the 8xxx(HT) is a second layer of a heat treatable 8xxx aluminum alloy product, which may or may not be produced in accordance with the processes disclosed herein.
  • Such multi-layer products may find applicability in packaging, automotive, aerospace and armor applications, among others.
  • the second layer comprises an aluminum alloy having improved weldability (e.g., for spot welding) as compared to the first aluminum alloy layer.
  • This second layer may be any aluminum alloy, heat treatable or non-heat treatable, that has good weldability. Examples of alloys having good weldability include 3xxx, 4xxx, 5xxx, 6xxx, and some low-Cu 7xxx alloys.
  • the second layer has a lower melting point than the first layer. Thus, during the welding of the first and second layers, the second layer may melt thereby creating a bond between the first layer and the second layer (i.e., the welding process results in creating an adhesive bond).
  • the second layer has a lower resistance than the first layer, which may be useful in spot welding applications.
  • the multi-layer products may be produced in a variety of manners.
  • the first and second layers are either (i) created together or (ii) coupled to one another prior to the cold working step (200).
  • the first and second layers may be created together during casting, such as via the casting techniques described in U.S. Patent Application Publication No. 20030079856 to Kilmer et al,, U.S. Patent Application No. 20050011630 to Anderson et al., U.S. Patent Application No. 20080182122 to Chu et al., and WO2007/098583 to Novelis (the so-called FUSIONTM casting process).
  • the first and second layers may be coupled together (i.e., cast separately and then joined) via adhesive bonding, roll binding, and similar techniques. Since the first and second layers are adjacent one another prior to the cold working step, both layers will receive at least 25% cold working due to the subsequent cold working step (200).
  • the multi-layer product may then be subsequently thermally treated (300).
  • the thermally treating step (3 0) may result in this second layer having higher ductility but lower strength as compared to the properties of that second layer in the as-cold worked condition.
  • the first layer is a new HT aluminum alloy processed in accordance with the processes disclosed herein, the first layer may realize both improved strength and ductility as compared to the properties of the first layer in the as-cold worked condition.
  • the multi-layer product may have tailored lower strength, higher ductility properties on the outer surface of the multilayer product, but with higher strength properties towards the inside of the multi-layer product. This may be useful, for example, in armor applications, with the first layer resisting penetration by a projectile and the second layer resisting spalling.
  • the first and second layers are coupled to one after the cold working step (200) and prior to the thermally treating step.
  • each layer may receive a tailored amount of post-solutiohizing cold work (if any for the second layer), but with the first layer receiving at least 25% cold working due to the cold working step (200).
  • the multilayer product may then be subsequently thermally treated (300),
  • the thermally treating step (300) may be used to achieve the coupling of the two layers (e.g., as the as an adhesive bonding curing step; that is, a thermally treating step may assist in adhesive bonding, which steps would be completed concomitant to one another in this embodiment),
  • the first and second layers are coupled to one after the thermally treating step (300).
  • each layer may receive a tailored amount of cold work and a tailored amount of thermal treatment, but with the first layer receiving at least 25% cold working due to the cold working step (200), and the first layer being thermally treated to achieve at least one improved property (e.g., a higher strength as compared to the as cold worked condition, or as compared to a reference version of the product in the T6 temper),
  • the multi-layer products may include a third layer, or any number of additional layers.
  • a multi-layer product includes at least three layers.
  • a layer of a new HT aluminum alloy product processed in accordance with the processes disclosed herein is "sandwiched" in between two outer layers. These two outer layers may be the same alloy (e.g., both the same lxxx alloy), or these two outer layers may be different alloys (e.g., one a lxxx aluminum alloy and the other another type of lxxx alloy; as another example, one a l xx alloy, the other a 5xxx alloy, so on and so forth),
  • the multi-layer product is a NHT-NEW-NHT product, where NHT stands for a layer of non-heat treatable alloy, as described above, and the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein.
  • the multi-layer product is a 3xxx-NEW-3xxx product, with the outer layers being xxx aluminum alloy product and with the inner layer being a new HT aluminum alloy product processed according to the processes disclosed herein.
  • Such multi-layer products may find utility in packaging (e.g., containers (cans, bottles, closures), trays or other configurations), in automotive applications (e.g., panels or body-in- white), aerospace applications (e.g., fuselage skin, stringers, frames, bulkheads, spars, ribs, and the like), and marine structural applications (e.g., bulkheads, frames, hulls, decks, and the like), to name a few).
  • automotive applications e.g., panels or body-in- white
  • aerospace applications e.g., fuselage skin, stringers, frames, bulkheads, spars, ribs, and the like
  • marine structural applications e.g., bulkheads, frames, hulls, decks, and the like
  • 5xxx*NEW-5xxx products could be used for the same or similar purposes.
  • Other combinations of NHT-NEW- NHT may be employed, and it is not required that the same NHT be used on both sides of the NEW layer, i.
  • the multi-layer product is a NEW(1)-HT-NEW(2) product, where HT stands for a layer of heat treatable alloy, as described above, and where at least one of the NEW(l) and NEW(2) is a layer of a new HT aluminum alloy product produced according to the new processes disclosed herein, which layers may have the same composition or different compositions,
  • both NEW(l) and NEW(2) layers have the same composition and are produced according to the new processes disclosed herein,
  • the NEW(l)- HT-NEW(2) Such products may be useful in automotive applications in closure panels, body- in-white (BIW) structure, seating systems or suspension components, among others. Such products might also be useful in commercial or military aerospace components, including launch vehicle or payload components.
  • Such components might further be useful for commercial transportation products in light, medium or heavy duty truck structure or buses.
  • the NEW-HT- NEW products could be useful in multi-piece wheels for autos, trucks or buses. Such products could also be useful for building panels. Such products could further be useful for armor components.
  • the multi-layer product is a NEW -NHT -NEW product, where NHT stands for a layer of a non-heat treatable alloy, as described above, and the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein.
  • NHT stands for a layer of a non-heat treatable alloy
  • the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein.
  • Such products may be useful in components used in marine applications for ships or boats and amphibious military vehicles.
  • Such products might also be useful for automotive applications in closure panels, BIW structure, seating systems or suspension components, among others, Such products might further be useful for packaging systems (e.g., containers (cans, bottles, closures), trays).
  • the NEW-NHT-NEW products might also be useful for lighting components.
  • the new HT alloy is combined with a HT alloy of lower strength, this could be useful in automotive crashworthy or energy-absorbing applications.
  • the multi-layer product is a HT(1)-NEW-HT(2) product, where HT stands for layers of a heat treatable alloy, as described above, which layers (HT(1) and HT(2)) may have the same or different compositions, and where the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein.
  • HT stands for layers of a heat treatable alloy
  • the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein.
  • Such products may be useful in commercial or military aerospace components, including launch vehicle or payload components.
  • the new HT alloy is combined with a HT alloy of higher strength, this could be useful in automotive crashworthy or energy- absorbing applications
  • the multi-layer product is a HT-NEW-NHT product, where HT stands for a layer of heat treatable alloy, as described above, NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein, and NHT stands for a layer of a non-heat treatable alloy, as described above.
  • HT stands for a layer of heat treatable alloy
  • NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein
  • NHT stands for a layer of a non-heat treatable alloy, as described above.
  • Such products may be useful in commercial or military aerospace components, including launch vehicle or payload components. Such products might also be useful for automotive applications in closure panels, BIW structure, seating systems or suspension components. Such products could be useful in automotive crashworthy or other energy- absorbing applications. Such components might further be useful for commercial transportation products in light, medium or heavy duty truck structure or buses. Such products could further be useful for armor components,
  • the multi-layer product is a NEW-NHT-HT product, where the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein, the NHT stands for a layer of a non-heat treatable alloy, as described above, and HT stands for a layer of heat treatable alloy, as described above.
  • Such products may be useful in commercial or military aerospace components, including launch vehicle or payload components. Such products might also be useful for automotive applications in closure panels, BIW structure, seating systems or suspension components. Such components might further be useful for commercial transportation products in light, medium or heavy duty truck structure or buses. Such products could be useful in automotive crashworthy or other energy-absorbing applications.
  • the multi-layer product is a NEW-HT-NHT product, where the NEW is a layer of a new HT aluminum alloy product produced according to the processes disclosed herein, the HT stands for a layer of heat treatable alloy, as described above, and NHT stands for a layer of a non-heat treatable alloy, as described above.
  • Such products may be useful in components used in marine applications for ships or boats and amphibious military vehicles. Such products might also be useful for automotive applications in closure panels, BIW structure, seating systems or suspension components. Such products might further be useful for packaging systems (e.g., containers (cans, bottles, closures), trays). Such products could also be useful for building panels. Such products could further be useful for armor components.
  • the NEW-HT- NHT products might also be useful for lighting components.
  • a method comprises casting an aluminum alloy body, wherein, after the casting, the aluminum alloy body comprises a first layer of a first heat treatable alloy, and a second layer of either a second heat treatable alloy or a non-heat treatable alloy (e.g., using the techniques described in commonly-owned U.S. Patent Publication No. US 2010/0247954 to Chu et al, which patent application is incorporated herein by reference in its entirety), (b). solutionizing the aluminum alloy body, (c) cold working the aluminum alloy body, wherein the cold working induces al least 25% cold work in the aluminum alloy body, and (d) thermally treating the aluminum alloy body.
  • an aluminum alloy body having a first layer and a second layer may be produced, and which layers may be distinct from one another.
  • the second layer comprises a second heat treatable alloy, In one embodiment, the second heat treatable alloy is different than the first heat treatable alloy. In another embodiment, the second heat treatable alloy is the same as the first heat treatable alloy (but are distinct layers).
  • This aluminum alloy body may realize improved strength, ductility, or other properties, such as any of the properties described in the Properties section (Section H), above,
  • the method comprises, after the thermally treating step, assembling an assembly having this aluminum alloy body having the at least first and second layers, In one embodiment, this aluminum alloy body having the at least first and second layers is an armor component. In another embodiment, this aluminum alloy body having the at least first and second layers is an automotive component.
  • a method comprises casting an aluminum alloy body, wherein, after the casting, the aluminum alloy body comprises a composition gradient, wherein a first region comprises a first composition, and a second region comprises a second composition, the second composition being more than just nominally different than the first composition (e.g., a compositional gradient beyond mere macrosegregation effects), Techniques available to produce such aluminum alloy bodies are described in commonly-owned U.S. Patent Publication No. 2010/0297467 to Sawtell et al., which patent application is incorporated herein by reference in its entirety.
  • the first composition is a composition that makes it a heat treatable aluminum alloy (i.e., capable of precipitation hardening), and the second region of the body has more than a nominally different composition than the heat treatable alloy of the first region.
  • a continuous concentration gradient exists between the first and second regions.
  • the continuous concentration between the first and second regions gradient may be linear, or may be exponential.
  • the aluminum alloy body comprises a third region.
  • the third region comprises the same concentration as the first region but is separated from the first region by the second region.
  • the concentration gradient between the first and second regions is linear. In some of these embodiments, the concentration gradient between the second and third regions is linear.
  • the concentration gradient between the second and third regions is exponential.
  • the aluminum alloy body having the purposeful composition gradient may be solutionized, and then cold worked, wherein the cold working induces at least 25% cold work in the aluminum alloy body, and then thermally treated.
  • an aluminum alloy body having a tailored composition gradient may be produced.
  • This aluminum alloy body may realize improved strength, ductility, or other properties, such as any of the properties described in the Properties section (Section IT), above.
  • the method comprises, after the thermally treating step, assembling an assembly having this aluminum alloy body having, the first region and the second region.
  • this aluminum alloy body having the at least first and second regions is an armor component.
  • this aluminum alloy body having at the first and second regions is an automotive component.
  • this aluminum alloy body having at the first and second regions is an aerospace component.
  • any number of additional aluminum alloy layers may be used in any of the above-described multi-layer approaches and/or embodiments.
  • any number of non-aluminum alloy layers e.g., plastic layers, resins / fiber layers
  • any of the above-described multi-layer products may be employed with the cold work gradient processing techniques described in the Cold Work section (Section B(iii)), above.
  • Examples of multi-layer product styles that may be employed with products made by the new processes disclosed herein include those described in, for example, U.S. Patent Application Publication Nos.
  • the preparing, cold working, thermally treating, and optional final treatment apparatus and methodologies described above in Sections A, B, C, and F > respectively, may be combined in any suitable manner as described herein to achieve any of the improved aluminum alloy bodies and/or properties described in Sections D and H, any of the microstrucrares described in Section E, and to achieve any of the aluminum alloy bodies and products described in any of Sections A-I, and the compositions provided for in Section G may be tailored, as appropriate to achieve such aluminum alloy bodies.
  • FIG. 1 is a flow chart illustrating a conventional process for producing aluminum alloy products.
  • FIG. 2a is a flow chart illustrating a new process for producing aluminum alloy products.
  • FIGS. 2b-2c are schematic views of example aluminum alloy bodies that may be cold worked to produce differential cold work zones or gradients.
  • FIGS. 2d-2f illustrate various manners of cold working the aluminum alloy bodies of FIGS. 2b-2c to produce cold worked aluminum alloy bodies having tailored cold worked zones, as well as the produced bodies themselves.
  • FIGS. 2g-2i illustrate other examples of aluminum alloy bodies that may be cold worked to produce differential cold work zones or gradients, one example of cold working such bodies, and the produced bodies themselves.
  • FIGS. 2j-21 illustrate various manners of producing cold rolled products having differential cold work zones or gradients.
  • FIG. 2m is a top-down view of the rolled aluminum alloy product produced via the process of FIG, 2j.
  • FIGS, 2n-2o illustrate various types of automotive components that may be produced in accordance with the new methods described herein.
  • FIGS. 2p-l to 2p-3 are exploded views of an automotive vehicle, illustrating various types of automotive components that may be produced in accordance with the new methods described herein.
  • FIGS. 2q-l to 2q ⁇ 9 are flow charts illustrating various example methods for producing improved aluminum alloy bodies.
  • FIG, 2r illustrates various schematic views of various aluminum alloy ammunition cartridges, in intermediate and final forms.
  • FIGS. 2s-l to 2s-5 are flow charts illustrating various example methods for producing improved aluminum alloy containers.
  • FIG. 2s-6 is a schematic side view illustrating one embodiment of an aluminum alloy container that may be produced in accordance with the new methods described herein,
  • FIG. 2s-7 is a schematic side view illustrating one embodiment of an aluminum alloy closure that may be produced in accordance with the new methods described herein.
  • FIGS. 2t-l to 2t-2 are schematic views illustrating one perspective view and a cross- sectional view, respectively, of an aluminum alloy wheel that may be produced in accordance with the new methods described herein.
  • FIGS. 3-5 are flow charts illustrating various embodiments of preparing an aluminum alloy body for post-solutiqnizing cold work.
  • FIG. 6a is a flow chart illustrating one embodiment of preparing an aluminum alloy body for post-solutionizmg cold work, where the solutionizing step is completed concomitant to a placing step (e.g., concomitant to a continuous casting step).
  • FIGS. 6b- 1 and 6b-2 are schematic views illustrating one embodiment of a continuous casting apparatus for preparing aluminum alloy bodies for post-solutionizing cold work in accordance with FIG. 6a.
  • FIGS. 6c-6f and 61-6k are graphs illustrating data associated with aluminum alloy bodies produced in accordance with the continuous casting apparatus of FIGS. 6b- 1 and 6b-2
  • FIGS, 6g-6j and 6m are micrographs of aluminum alloy bodies produced in accordance with the continuous casting apparatus of FIGS. 6b- 1 and 6b-2.
  • FIGS. 6n and 6o are schematic views illustrating an optional strip support mechanism that may be employed with the continuous casting apparatus of FIGS 6b- 1 and 6b-2.
  • FIG. 6p is a flow chart illustrating one embodiment of completing a concomitant casting and solutioriizing step to produce an aluminum alloy body having particulate matter therein. .
  • FIG. 6q is a schematic view illustrating one embodiment of a continuous casting apparatus for preparing aluminum alloy bodies for post-solutionizmg cold work in accordance with FIGS. 6a and 6p, where such aluminum alloy bodies contain particulate matter therein.
  • FIGS. 6r-6s are micrographs of aluminum alloy bodies produced in accordance with the continuous casting apparatus of FIGS. 6q having particulate matter therein,
  • FIG. 6t is a flow chart illustrating one embodiment of completing a concomitant casting and solutionizing step to produce an aluminum alloy body having immiscible metal therein.
  • FIGS. 6u-6w are schematic views illustrating one embodiment of a continuous casting apparatus for preparing aluminum alloy bodies for post-solutionizing cold work in accordance with FIGS. 6a and 6t, where such aluminum alloy bodies contain immiscible metal therein.
  • FIG. 6x is a micrograph of an aluminum alloy body produced in accordance with the continuous casting apparatus of FIGS. 6u-w having immiscible metal therein.
  • FIGS. 7-8 are flow charts illustrating embodiments of preparing an aluminum alloy body for post-solutionizing cold work.
  • FIG. 9 is a flow chart illustrating one embodiment of a method for producing a rolled aluminum alloy body.
  • FIG. 10 is a graph illustrating R-values as a function of orientation angle for various aluminum alloy bodies.
  • FIGS. 11 a- l ie are optical micrographs illustrating aluminum alloy body microstructures; the optical micrographs were obtained by anodizing the samples and viewing them in polarized light.
  • FIGS. 1 1 g- 1 If are optical micrographs of aluminum alloy bodies.
  • FIG. 12 is a flow chart illustrating one method of producing multi-layered aluminum alloy products.
  • FIG. 13 is a schematic view illustrating the L, LT and ST directions of a rolled product.
  • FIGS. 14-22 are graphs illustrating the thermal treatment response of various 6xxx aluminum alloy bodies.
  • FIG. 23 is a graph illustrating the ductility of various 6xxx aluminum alloy bodies as a function of time when thermally treated at 350°F.
  • FIG. 24 is a graph illustrating the fatigue response of various 6xxx aluminum alloy bodies.
  • FIG. 25 is a graph illustrating trendlines of the fatigue response of various 6xxx aluminum alloy bodies based on the data of FIG. 24,
  • FIG. 26 is a graph illustrating the strength and fracture toughness properties of various 6xxx aluminum alloy bodies.
  • FIGS. 27-35 are graphs illustrating various properties of various 6013 alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
  • FIG. 36 is a graph illustrating various properties of various 6061 alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
  • FIG. 37 is a graph illustrating various properties of various 6022 alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
  • FIGS. 38-39 are graphs illustrating -values as a function of orientation angle for various 6022 and 6061 aluminum alloy bodies.
  • FIGS. 40-51 are graphs illustrating various properties of high magnesium 6xxx aluminum alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
  • FIG. 52 is a photograph illustrating a predetermined shaped product made from a AA61 11 sheet product produced in accordance with the new processes disclosed herein, wherein a portion of the thermal treatment step comprises forming of the predetermined shaped product.
  • FIGS. 53-59 are forming limit diagrams produced from various predetermined shaped products formed at various temperatures.
  • FIG. 60 is a photograph illustrating a predetermined shaped product made from a AA61 1 1 sheet product produced in accordance with the new processes disclosed herein, where the thermal treatment step is completed prior to the forming step, and the forming step is completed at room temperature.
  • FIGS. 61-62 are forming limit diagrams produced from various predetermined shaped products formed at room temperature.
  • FIG. 63 is a graph illustrating strength versus cold work amount for various tread sheet products produced in accordance with the new processes disclosed herein.
  • FIG. 64 is a cross-sectional, schematic side view of a wheel similar to that prepared in Example 9.
  • FIG. 65a is a cross-sectional view of a wheel similar to that prepared in Example 9,
  • FIG. 65b is a front view of a wheel similar to that prepared in Example 9.
  • FIGS. 66-71 are various graphs illustrating properties of the wheels of Example 9.
  • FIG. 72 is a graph illustrating strength properties of a rod of Example 1 1.
  • FIG. 73 is a graph illustrating dome reversal pressure properties as a function of baking time for various containers of Example 12.
  • FIGS. 74-93 are graphs illustrating the isochronal thermal response of various aluminum alloy bodies of Example 13.
  • FIGS. 94-102 are graphs illustrating the thermal treatment response of various aluminum alloy bodies of Example 14.
  • FIG. 103 is a graph illustrating tensile yield strength as a function of silicon plus copper for various example alloys
  • FIGS. 104-107 are graphs illustrating the thermal treatment response of various aluminum alloy bodies of Example 15.
  • FIG. 108 is a graph illustrating the through-thickness concentration profile for Si and Mg of Alloy CC6 of Example 17.
  • FIG. 109 is a graph illustrating R- values as a function of orientation angle for various aluminum alloy bodies.
  • FIGS. 110a and 110b are graphs illustrating push force and tear force, respectively, function of iron content.
  • Example 1 Testing of 6xxx aluminum alloy having copper and zinc
  • a 6xxx aluminum alloy having both copper and zinc (the "6xxx+Cu+Zn alloy") is direct chill cast as an ingot. This alloy is similar to that disclosed in U.S. Patent No. 6,537,392.
  • the 6xxx+Cu+Zn alloy has the composition provided for in Table 3, below.
  • the ingot After casting, the ingot is homogenized and then hot rolled to an intermediate gauge of 2.0 inches.
  • the 2.0 inch body is split into five sections, bodies A-E.
  • Body A is conventionally processed into sheet by hot rolling the 2,0 inch plate to a second intermediate gauge of 0,505 inch, then cold rolling into sheet having a final gauge of 0.194 inch, after which it is solutionized (Sheet A), stretched about ' 1% for flatness,
  • Bodies B-E are processed into sheet using the new process by hot rolling to second intermediate gauges of 1.270 inches (Body E), 0.499 inch (Body D), 0.315 inch (Body C , and 0.225 inch (Body B), and then solutionizing, and then cold rolling these bodies to a final sheet gauge of about 0.200 inch.
  • Sheet B .receives about 1 1% CW, .
  • Sheet C receives about 35% CW, Sheet D receives 60% CW and Sheet E receives about 85% CW.
  • Test 1 Samples :
  • a sample of Sheet A is thermally treated at 3 SOT. Since Sheet A was solutionized and then thermally treated, i.e., no cold work was applied between the solutionizing and thermal treatment step, Sheet A is considered to be treated to a T6 temper. The mechanical properties of the sample from Sheet A are measured as a function of time at various intervals.
  • Various samples from Sheets B-E are thermally treated. A first set is thermally treated at 300°F, a second set is thermally treated at 325°F, a third set is thermally treated at 350°F, a fourth set is thermally treated at 375°F, and a fifth set is thermally treated at 400°F.
  • the mechanical properties of each the samples from of Sheets B-E are measured as a function of time at various intervals.
  • FIGS.. .14-23 illustrate the thermal treatment response of Sheets A-E.
  • the sheets made by the new process (Sheets B-E) achieve higher strength and in a shorter period of time relative to the conventional sheet product (Sheet A).
  • Table 4, below illustrates some of the tensile properties using the 350T thermal . treatment condition, all values in ksi and in the LT (long transverse) direction.
  • Sheets C-E made by the new process and having at least 25% cold work realize an increase in strength over Sheet A.
  • Sheet E with 85% CW and thermally treated at 350°F realizes about a strength of 70.9 ksi and with only 2 hours of thermal treatment (its peak strength may be higher since it achieved high strength so quickly).
  • the conventionally processed sheet (Sheet A) in the T6 temper reaches its measured highest strength around 16 hours of thermal treatment, and then only realizes a strength of about 55.3 ksi.
  • Sheets C, D and E with more than 25% cold work realize tensile yield strengths in excess of 60 ksi.
  • Sheets D and E with 60% and 85% cold work, respectively realize tensile yield strengths in excess of 65 ksi, indicating that more than 35% cold work, such as more than 50% cold work, may be required to regularly achieve tensile yield strengths in excess of 60 ksi for this particular alloy.
  • FIGS, 19-21 illustrate the yield strengths for Sheets B-E at various thermal treatment temperatures, As illustrated, at higher thermal treatment temperatures the time required to attain a given yield strength gets progressively shorter. Due to this short thermal treatment time, it is possible that paint baking cycles or coating cures could be used to thermally teat new 6xxx aluminum alloy bodies, making them particularly useful for automotive applications and rigid container packaging applications, among others. [00406] Given these significant strength increases, a significant drop in ductility would be expected for Sheets B-E. However, as shown in Table 5, below and FIG. 23, the 6xxx+Cu+Zn aluminum alloy bodies realize good elongation values. All elongation values are in percent. Similar elongation values are measured for the samples thermally treated at 300°F, 325°F, 375°F, and 400°F. ,
  • Test 2 Samples - Mechanical Properties
  • Samples from Sheets A-E are thermally treated, the conditions of which are provided in Table 6, below ("the test 2 samples”). Mechanical properties are measured, the averages of which are also provided in Table 6, Sheets C-E of the new process and having more than 25% cold work achieve higher strengths than the Sheet A product of the old process, and in all directions, while Sheet B with less than 25% cold work realizes similar properties to that of Sheet A.
  • Test 2 Samples - Fatigue
  • test 2 samples from Sheets A-E are also subjected to strain fatigue testing in accordance with ASTM E606, the results of which are illustrated in FIGS. 24-25.
  • the sheets made by the new process and with more than 25% cold work realize high cycle fatigue performance over the conventionally processed material, i.e., Sheet A in the T6 temper. In the low cycle (high strain) regime, these sheets are similar or better than Sheet A.
  • the test 2 samples from Sheets A-E are subjected to fracture toughness testing in accordance with ASTM E561 and B646.
  • the fracture toughness is measured using M(T) specimens with a width of about 6.3 inches and a thickness of about 0.2 inch, with an initial crack length of from about 1.5 to about 1.6 inches (2ao).
  • the measured ⁇ values from the fracture toughness test are provided in Table 7, below. The above-noted strength values are also reproduced for convenience.
  • Sheets D-E realize only slightly lower fracture toughness than Sheet A, even though Sheets D-E have much higher strength. All of the results are within a relatively narrow range of -57 to 63 ksiVin.
  • R-curve data indicates that, despite the range in strength of the material, all of Sheets A-E have similar R-curves.
  • FIG. 26 illustrates the strength and fracture toughness values using the K app values of Table 7 and the LT strength values of Table 6.
  • the new alloy bodies produced by the new process and having more than 25% cold work realize a similar or better combination of strength and fracture toughness relative to the conventionally produce T6 product. For example, Sheet E of the new process with 85% CW realizes about a 37% increase in strength, with only about a 1.6% decrease in fracture toughness over Sheet A in the T6 temper.
  • Test 2 Samples - Corrosion Resistance
  • the new 6xxx+Cu+Zn alloy bodies with more than 25% cold work have a predominately unrecrystallized microstructure, having a volume faction of not greater than 0, 12 first type grains (i.e., 88% unrecrystallized) in all instances. Conversely, the control body is nearly fully recrystalli zed having a volume fraction of 0.98 first type grains (i.e., 2% unrecrystallized).
  • the new 6xxx+Cu+Zn alloy bodies with 60% and 85% cold work also realize about 369% to 717% higher maximum R-values as compared to the R-value of the control body (for the purpose of measuring R-values, the control is in the T4 temper, not the T6 temper).
  • Example 2 Multi-layered product testing in the form of can body stock
  • multi-layered products comprising AA3104 as the cladding and AA6013 as the core is produced similar to the methodology of FIG. 12, described above, and in the H temper.
  • the multi-layered product is produced in both the 2-layer (3014-6013) and the 3-layer (3104-6013-3104) form.
  • the mechanical properties of the multi-layered products are tested in both the Hlx temper and after curing of the coating. The results are provided in Table 10, below.
  • All multi-layered products realize an improved combination of strength and ductility over the standard 3104 alloy product, realizing an increase in TYS (after cure) of from about 17 ksi to 30 ksi, and with similar or better ductility; - ' -The clad' layer of 3104 may be used to restrict pick-up Of aluminum and oxides on the ironing dies during can making.
  • the core layer of 6013 may be thermally treated during the coating cure, which may increase, its strength.
  • Aluminum Association alloy 6013 is produced in manner similar to that of Example 1, and its mechanical properties are measured. Alloy 6013 is a zinc-free, copper-containing 6xxx alloy. The composition of the tested 6013 alloy is provided in Table 1 1, below. The mechanical properties are illustrated in FIGS. 27-35.
  • Alloy 6013 achieves a peak LT tensile yield strength of about 64-65 ksi with 75% cold work and 60-61 ksi with 55% cold work, which is several 8-13 ksi higher than the peak strength of the control alloy (T6).
  • the 75% and 55% cold worked alloys realize these strengths faster than the control (T6) alloy.
  • the optical properties of the control, 55% cold work and 75% cold work 6013 sheets is evaluated using a Hunterlab Dorigon II (Hunter Associates Laboratoiy INC, Reston, VA).
  • the sheets are first mechanical polished to a mirror finish, cleaned, chemically polished, anodized to 0.3 mil oxide thickness and sealed.
  • the specular reflectance, image clarity and 2 degree diffuseness are measured to quantify the appearance of the anodized surface. Higher specular reflectance and image clarity values are indicative of brighter and more uniform appearance. Lower 2 degree diffuseness indicates a reduced level of haze in. the reflected image.
  • High specular reflectance and image clarity and low 2 degree diffuseness are valued for applications where the product is used as a reflector (as in lighting applications) and in other consumer electronics applications where a bright, uniform surface may be desired. Having aluminum alloy products with bright surfaces and high strength may be advantageous in these (and other) applications.
  • the measured optical properties of these 6013 sheets are provided shown in Table 15. As shown in the table, the optical properties for the 55% and 75% cold work 6013 sheets are improved over the control. The 55% and 75% cold work 6013 sheets also have improved strength, as shown above,
  • Aluminum Association alloys 6022 and 6061 are produced in manner similar to that of Example 1 , and their mechanical properties are measured. Alloy 6022 is a low copper, zinc- free alloy, having 0,05 wt. % Cu. Alloy 6061 is another low-copper, zinc-free alloy, having 0.25 wt.% Cu. The compositions of the tested 6022 and 6061 alloys are provided in Tables 12 and 13, below. The mechanical properties are illustrated in FIGS. 36-37.
  • alloy 6022 nor 6013 is able to achieve an LT tensile yield strength of more than 60 ksi.
  • the results of Examples 1-4 indicate that the strengthening response of an alloy relative to the new process disclosed herein may be dependent upon the type and amount of alloying elements used. It is believed that alloying elements that promote strain hardening and/or precipitation hardening may provide improved properties. It is also believed that the alloys may require sufficient solute to achieve improved properties. It is believed that the 6xxx+Cu+Zn alloy and the 6013 alloy are able to achieve the more than 60 ksi strengths because they contain sufficient solute (e.g. additional copper and/or zinc) to facilitate a high degree of hardening response (strain and/or precipitation). It is believe that alloys 6061 and 6022 do not achieve the 60 ksi strength level because they do not appear to have sufficient solute to facilitate a high degree of hardening response when high cold working and an appropriate thermal treatment are applied.
  • the R- alues of the 6061 and 6022 alloys are also tested as per the R- value generation procedure, described above, the results of which are illustrated in FIGS. 38-39.
  • the results indicate that these alloys have a different microstructure than the higher solute 6xxx+Cu+Zn and 6013 alloys.
  • the 6022 alloy (FIG. 38) does not have a maximum R-value in the orientation angle range of from 20° to 70°, as was realized by the 6xxx+Cu+Zn alloy. Indeed, the shape of the R-curve nearly mirrors the control specimen, realizing its maximum R- value at an orientation angle of 90°. As shown in FIG. 39, the 6061 alloy attains a maximum R- value at an orientation angle of 45°, but achieves an R-value of less than 3.0.
  • a 6xxx alloy with high magnesium (6xxx-high-Mg alloy) is produced in sheet and plate form in a manner similar to that of Example 1.
  • the final thickness of the sheet is 0.08 inch and the final thickness of the plate is 0.375 inch.
  • the composition of the 6xxx-high-Mg alloy is provided in Table 14, below.
  • the 6xxx-high-Mg alloy has low copper at 0.14 wt. % and is zinc- free (i.e., contains zinc only as an impurity).
  • the mechanical properties of the 6xxx-high-Mg alloy are illustrated in FIGS. 40-51.
  • the 6xxx -high-Mg alloy in sheet form achieves an LT tensile yield strength of more than 60 ksi when cold worked and with good elongation.
  • the results of Examples 4 and 5 show that such high-Mg 6xxx alloys may achieve at least 60 ksi LT yield strength, with low levels of copper and without zinc (i.e., zinc as an impurity only).
  • the high magnesium may promote a strain hardening response and/or precipitation hardening response.
  • Other high-magnesium alloy bodies may realize a strength level of less than 60 ksi, but may still find utility in various product applications.
  • Example 6 Warm forming of predetermined shaped products
  • Aluminum alloys AA61 11 and AA6013 were prepared for post-solutionizing cold work and then cold rolled to final gauge (0.035 inch sheet for AA6111 and 0.050 inch sheet for AA6013), thereby inducing about 74% cold work in the AA61 11 sheet, and about 55% in the AA6013 sheet. A portion of the 61 1 1 sheet is removed and thermall treated (30 minutes at 325°F)..
  • Samples of the 61 1 1 (both in the T3 and thermally treated conditions) and the 6013 sheets are warm formed into predetermined shaped products at temperatures of 375 °F and 400°F; AA611 1 is also warm formed at 350°F (collectively, the "warm formed parts”).
  • the warm forming is accomplished using a warm forming laboratory press to perform Nakajima Limiting Dome Height (LDH) tests, with a 4 inch diameter ball punch and with the part clamped around perimeter.
  • LDH Nakajima Limiting Dome Height
  • a high temperature solid lubricant (graphite) was used on the portions of the sample that were contacted by the punch.
  • FIG. 52 is a photograph illustrating one of the warm formed parts (6111 thermally treated prior to warm forming). Standard AA611 1 in the T6 temper (cold rolled, and then solutionized, and then artificially aged) is also warm formed in accordance with the foregoing for comparison purposes.
  • forming limit diagrams are produced based on the warm formed parts and based on ASTM E2218-02 (2008), except that a high temperature lubricant was used, only three (3) geometries were used and only two (2) replicates were used due to material availability, Those forming limit diagrams and corresponding forming limit curves are illustrated in FIGS. 53-59. Strain measurement was accomplished by electro -etching a circle grid onto the surface prior to the warm forming operation. This grid is indelible and can withstand high temperature.
  • FIG. 60 is a photograph illustrating one of the room temperature formed parts. Standard AA61 11 in the T6 temper (cold rolled, and then solutionized, and then artificially aged) is also formed at room temperature for comparison purposes. The room temperature forming results are illustrated in FIGS. 61-62.
  • the new 6111(T3) alloy formed at 400° achieved about a 5.5 ksi increase in tensile yield strength as compared the room temperature formed version of that alloy, This alloy also realized about 14 ksi higher yield strength than the 61 11(T6) version of the product.
  • the 61 1 1 (T3) alloy realized similar forming ductility properties as the 61 1 1(T6) alloy even with the higher strength.
  • the 611 1 (T3) alloy realized a FLDo of 0.
  • the 6111 (T3) products realize much higher strengths than the 61 11 (T6) products with similar, ductility and formability, and with only a few minutes of thermal exposure during the warm ' forming.
  • a warm forming step can be used as die thermal treatment step (300), or as a portion of the thermal treatment step (300), to produce predetermined shaped aluminum alloy products using the new processes disclosed herein.
  • a first heating step may be used as part of the thermal treatment step (300), which may be conducted prior to the warm forming, and the warm forming may be used as another part of the thermal treatment step (300).
  • the thermal treatment step (300) may consists of warm forming, i.e., the warm forming is the only thermal treatment applied to the aluminum alloy body.
  • warm forming is an option to produce defect-free predetermined shaped products from aluminum alloy bodies having a high amount of cold work, and with increasing strength.
  • a 6xxx sheet or plate may be supplied for warm forming in any of the as-cold worked condition, the T3 condition, or after a first heating step in the form of a partial thermal treatment has been applied to the 6xxx alloy, The 6xxx product may then be warm formed into the predetermined shaped automotive component, which warm forming may actually increase the strength of the component.
  • An optional paint bake cycle may also be applied after the warm forming, which may also increase the strength of the component.
  • An optional additional thermal treatment may be applied between the warm forming and the paint bake.
  • the above-described first heating step may underage the component, as described above, or may age the component to peak or near peak strength, or may overage the component,
  • the warm forming and optional additional thermal treatment steps and/or optional paint bake steps may thus be tailored to increase strength and ductility,, or to decrease strength and increase ductility, depending on the need of the particular situation. Examples of some automotive components that may benefit from such warm forming operations include body-in-white (A, B or C pillars), door guard beam, a roof header and a rocker, to name a few.
  • 6xxx sheet and plate products may be supplied to automotive manufacturers with tailored / predetermined properties (e.g., due a predetermined underaging amount) that may be further improved upon by the automotive manufacturer during subsequent Warm forming, paint bake and/or other thermal treatment operations.
  • Similar processes could be used in other industries, such as aerospace (e.g., wing skins), marine (e.g., ship parts), rail ' (e.g., for hopper cars, or other related rail transportation vehicles), commercial vehicles (e.g., tractor trailers, vans, buses), and space launch vehicles, and many others of the above-described aluminum alloy products listed in the Product Applications section (Section I), above.
  • Suitable forming operations that may be conducted at thermal treatment temperatures to achieve the warm forming include, for example, stamping, hydroforming (with gas or liquid), bending, stretch forming, roll forming, embossing, hammering, joggling, hemming, flanging, spinning, deep drawing, and ironing, to name a few.
  • Defect-free means that the components are suitable for use as a commercial product, and thus may have little (insubstantial) or no cracks, wrinkles, Ludering (Luder bands), thinning and orange peel, to name a few.
  • All of the 6xxx alloys realized improvements in strength. Indeed, the 6xxx+Cu+Zn alloy realized about a 14% increase in LT TYS, and the 6xxx-high-Mg alloy realized about a 35% increase in LT TYS as compared to a reference version of the tread sheet that was not cold worked, but was aged for about 8 hours. These improvements are also realized with only about 25-35% cold work.
  • the 6061 alloy also realizes an increase in LT TYS (about 1 1%), but requires more cold work to achieve improved properties.
  • Example 8 Consumer Electronic Products i, Forming and Dent Resistance Testing
  • Aluminum alloy AA6111 was prepared for post-solutionizing cold work and then cold rolled to a final gauge of 0.0365 inch, which cold rolling induced about 75% cold work ("new 61 1 1 "), A comparison AA61 11 sheet material (0.035 inch) was prepared by cold rolling to final gauge, and then solutionizing ("Std. 61 11"). Some of these sheet products are then preheated in an oven at a temperature of about 300°F for about 30 minutes, after which they are placed in a preheated stamping die (9 inch by 12 inch), and then stamped into a laptop cover. Others of these sheet products are stamped at room temperature. The die was preheated by stamping several preheated blanks of the same temperature as the sheet products.
  • the new aluminum alloy products formed achieved similar results as compared to conventional 6061-T6 products in terms of formability, only having minor center doming and minor springback (approx. 1 mm) as compared to 60 1-T6. These minor deficiencies may be corrected using a die design tailored to the new products. Unexpectedly, distortion (twisting) of the lap top covers increased with increasing forming temperature, indicating that room temperature or low temperature forming may be advantageous in the production of consumer electronic and other stamped products.
  • the new 61 1 1 products also realize improved dent resistance, As shown in Table 18a, below, the new 611 1 products achieve smaller dents when tested according to the below- described Dent Test Procedure. Standard 6061 -T6 and 5052-H32 were also tested at room temperature for comparison purposes. Since the sheets were of different thickness, the dent resistance was normalized by talcing the inverse of the dent size, and then dividing by the sheet thickness (e.g., for New 61 1 1 , the dent size is inversed, which equals 20.408 inch "1 , which is then divided by the sheet thickness of 0,0365 inch to achieve a normalized dent resistance of 559 per inch 2 .
  • the new 611 1 alloys realize about 33% higher dent resistance at room temperature as compared to the conventionally produced 611 1-T4 product, and about 29% higher dent resistance at 300°F as compared to the conventionally produced 6111 thermally treated product.
  • the new 61 1 1 alloys also realize about 57% higher room temperature dent resistance as compared to conventional alloy 5052-H32, and about 18% higher room temperature dent resistance as compared to the conventional alloy 6061-T6.
  • Procedure Place sample to be dented under the half inch impact ball and raise the 2 lbs weight to number 10 on slide (i.e., to get to 10 inch pounds of force). Drop the weight and dent the sample. Measure the depth of the dent using the dial depth gauge, and record. If the impact ball penetrates the sample, reduce the weight to 1 lb., or less, to avoid penetration. If the depth of the dent is less than 0.010 inch, increase the weight to 5 lbs, or greater to achieve a minimum depth of dent of 0.010 inch. ii. Surface Appearance
  • the new 61 1 1 sheet is also tested for surface appearance characteristics. Specifically, the new 6111 sheet is mechanically polished to a mirror finish, after which it is cleaned in an alkaline non-etch cleaner for about 2 minutes at about 140°F, then chemically brightened in an acid bath (primary components were phosphoric acid and nitric acid) for 2 minutes at 225°F, and then de-smutted in a 50% nitric bath for about 30 seconds at room temperature. The sample was then anodized in a 20%» sulfuric acid anodizing bath at 70°F and 12 amps per square foot, to achieve an oxide thickness of about 0,3 mil (0.0003 inch), after which it was sealed in a nickel acetate bath for about 10 minutes at about 205°F.
  • the new 61 1 1 alloys realizes a higher gloss value than the other alloys, meaning that the newly processed alloys may not only realize improved mechanical properties, but may also realize improved surface appearance properties.
  • An aluminum alloy body comprised of aluminum alloy 6061 was solutionized, and then cold worked into a wheel via flow forming.
  • the resulting wheel is similar to the wheels illustrated in FIGS, 64, 65a and 65b.
  • Position No. 1 of the wheel, located on the mounting flange of the wheel has received no cold work from flow forming.
  • Position No. 2, located on the rim, more specifically, the drop well, has received about 54% cold work from the flow forming.
  • a first portion of Wheel A containing both Position No. 1 and Position No. 2 was then thermally treated for fifteen (15) hours at 350° F.
  • a second portion of Wheel A containing both Position No. 1 and Position No. 2 was thermally treated for eight (8) hours at 385° F.
  • a second aluminum alloy body comprised of the same 6061 alloy as Wheel A was cold worked and then solutionized, i.e., placed into a T4 temper.
  • a first portion of Wheel B containing both Position No. 1 and Position No, 2 was thermally treated for fifteen (15) hours at 350° F.
  • a second portion of Wheel B containing both Position No, 1 and Position No, 2 was thermally treated for eight (8) hours at 385° F.
  • FIG. 66 The tensile yield strength curves resulting from thermal treatment at 350° F are illustrated in FIG. 66.
  • Position No. 2 of Wheel A having about 54% cold work, has an improvement in tensile yield strength over the tensile yield strength of Wheel A at Position 1, having no cold work, and both Position 1 and Position 2 of Wheel B, which was in the T4 temper before being thermally treated.
  • the ultimate tensile strength curves (FIG, 67) reflect similar improvements at Position No. 2 .
  • FIG., 68 The elongation curves resulting from the thermal treatments at 350° F are illustrated in FIG., 68. It can be seen that Wheel A at Position No. 2 maintains an elongation percent comparable to Wheel A at Position 1 and both Position 1 and Position 2 of Wheel B, even though Wheel A at Position 2 has an improvement in tensile yield strength.
  • FIGS. 69 and 70 The tensile yield strength and ultimate tensile strength curves resulting from thermal treatment at 385° F are illustrated in FIGS. 69 and 70, respectively. Similar to the 350°F curves, Position No. 2 of Wheel A has significant strength improvements over the tensile yield strength of Wheel A at Position 1, having no cold work, and both Position 1 and Position 2 of Wheel B, which was in the T4 temper before being thermally treated, Also, as can be observed in FIG. 71, after the thermal treatment of eight (8) hours at 385° F, Wheel A at Position No.
  • the first zone which received essentially no cold work, has higher ductility than the third zone, having an elongation of about 21% in all directions, whereas the third zone has much lower ductility, having from about 7.5% elongation to about 9.5% elongation, depending on measurement direction.
  • the third zone has about 30 to 32 ksi higher tensile yield strength than the first zone in the L and LT directions, respectively, which is more than 100% higher in both cases.
  • the third zone also has about 16 ksi higher ultimate tensile strength than the first zone in both the L and LT directions.
  • This type of aluminum alloy body, having tailored cold work may be useful in many of the applications noted above, such as an automotive component, where the first zone may be useful as a tailored energy absorbing zone and the third zone may be useful as a tailored reinforcement zone.
  • Rods were manufactured from aluminum alloy 6201 and a version of the 6xxx+Cu+Zn alloy by preparing an intermediate material for post-solutionizing cold work, then cold working the intermediate material to various final gauges, and then thermally treating at various temperatures for various times. These alloys were also conventionally prepared by cold working, then solutionizing, and then thermally treating at various temperatures for various times. The ultimate tensile strength (L) and elongation (L) of the rods were determined according to ASTM E8 and B557 for a variety of thermal treatments, the results of which are provided in Tables 20-24, below.
  • the new 6xxx rods achieved improved properties over the conventionally prepared rod materials. Indeed, the new 6201 rods achieve from about 5% to about 38% improvement in ultimate tensile strength as gompared to the similarly processed conventional 6201 rods, and in a shorter thermally treatment time.
  • the new 6xxx+Cu+Zn alloy rods achieve similar improvements.
  • FIG. 72 shows the performance of a new 6201 alloy rod product having about 2.49 equivalent plastic strain (EPS) as compared to conventional 6201 in the T81 temper.
  • EPS plastic strain
  • the new 6201 alloy realizes about 5% higher ultimate tensile strength at the same thermal treatment time of 8 hours.
  • such improved strength could be used to down gauge existing containers to achieve the same strength at less weight, or to produce containers having improved strength at similar weight, among other options.
  • suppliers of aluminum alloy bodies may be able tailor their cold working and/or thermally treating steps so that the container manufacturer, upon receipt and processing of such alloy bodies, achieves a predetermined strength and/or elongation, such as a peak or near peak strength condition, among others, and as described in the Thermal Treatment section (Section C, subsection i), above.
  • Example 13 Continuous Casting of Various Aluminum Alloys
  • Various aluminum alloys compositions are prepared for post-solutionizing cold work by continuously cast according to the practices described above relative to FIGS. 6b-l and 6b-2.
  • the compositions of the.cast alloys are provided in Table 26, below.
  • the alloys were then hot rolled to -0,050 to 0,060" gauge and then cold water quenched.
  • the quenched samples were cold rolled to three intermediate gauges of -0.042 inch, -0.031 inch and -0.025 inch. These samples were then solutionized at about 1000°F for about 30 seconds, and then cold water quenched, and then cold rolled to final gauge, inducing from about 60% - 85% post-solutionizing cold work, depending on alloy.
  • Mechanical properties of the alloys were then obtained.
  • the alloys were then thermally treated for 2 hours at several different temperatures (250°F, 275°F, 300°F, 325°F, and 350°F).
  • Fe and Mn are known to participate in the formation of the phase Al] 2 (Fe,Mn) 3 Si, which phase also requires Si.
  • the presence of high levels of Fe and Mn can lead to a lowering of the amount of Si available for age hardening.
  • Fe+Mn should be ⁇ .1.5 in order to facilitate an age hardening response.
  • aluminum alloys falling within the above compositions, and having either (i) Cu+Si > 0.6, or (ii) Cu+Si ⁇ 0.6 and Fe+Mn ⁇ 1.5, and receiving at least 25% post-solutionizing cold work may realized improved properties.
  • Alloy CC8 at 75% cold work realized the largest increase in yield strength (7.8 ksi) as compared to the aluminum alloy body in the as-cold work condition. These results indicate that higher levels of cold work (e.g., at least 75%) may be beneficial in obtaining continuously cast products having improved properties.
  • Alloys CCl 9 and CC20 also had higher amounts of zinc and did not appear to have a detrimental effect on strength. Furthermore, zinc is highly soluble in aluminum, Thus, it is anticipated that the new alloys may include zinc in amount of up to 1 ,5 wt. % without materially affecting strength properties. In one embodiment, zinc is the predominant alloying element of the alloy other than aluminum.
  • Example 14 Additional Testing of Some Example 13 Aluminum Alloys
  • Example 13 alloys are re-solutionized, and then cold rolled to final gauge (about 0.020 inch) inducing about 80% cold work, and then thermally treated at 275 °F and 325°F for various times.
  • alloys CC2. CC3, CC4, CC8, CC12, CC15, CO 8, CC19, and CC20 are processed.
  • the mechanical properties were obtained in accordance with ASTM standards E8 and B557.
  • the tensile yield strength results are illustrated in FIGS, 94-102, Table 30, below, contains mechanical property data. All alloys achieved both improved strength .and ⁇ ductility ⁇ ' over the reference version of the ! allo . iii the ; as- cold worked condition.
  • the remainder of the alloys was aluminum and other elements, with no other element exceeding 0.05 wt. %, and with the total of such other elements not exceeding 0.15 wt. %.
  • each of the alloys was cold rolled about 35%, 60%, and 80% and then thermally treated.
  • a portion of each alloy was also processed to a T6- style temper by cold rolling to final gauge prior to solutionizing, after it was solutionized and then thermally treated.
  • Mechanical properties of the alloys are provided in Table 32, below, and the tensile yield strength results are illustrated in FIGS. 104-107.
  • Example 17 Microstructure of Continuously Cast Alloys
  • Alloys CC6 and OC18 were processed to induce about 57% cold work.
  • the microstructures of some of the continuously cast alloys were obtained by backscattered electron imaging, the results of which are illustrated in FIG. l lf-1 lg (approximate centeriine shown via dashes), These micrographs show a distinct three-layer structure, with two outer regions and an inner region disposed within the two outer regions. These micrographs indicate that alloys that are continuously cast .
  • a concentration profile of this Alloy CC18 having about 57% cold work is also obtained, per the Concentration Profile Procedure, described in Section (A)(i)(a), above, the results of which are provided in Table 34, below, and are illustrated in FIG. 108.

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Abstract

L'invention concerne de nouveaux corps en alliage d'aluminium HT et leurs procédés de production. Les nouveaux corps en alliage d'aluminium HT contiennent: 0,20 à 2,0% en poids de Mg; 0,10 à 1,5% en poids de Si; 0,01-1,0% en poids de Fe; et 0,10 à 1,0% en poids de Cu; de sorte que, lorsque Si + Cu < 0,60% en poids, alors Fe + Mn ≤ 1,5% en poids, avec éventuellement jusqu'à 1,5% en poids de Mn et éventuellement jusqu'à 1,5% en poids de Zn. Au moins l'un des éléments Mg, Si, Fe, Cu, le Mn facultatif et le Zn facultatif est, en dehors de l'aluminium, l'élément d'alliage prédominant de la feuille d'alliage d'aluminium, et peut être produit par préparation du corps en alliage d'aluminium pour écrouissage consécutif à la mise en solution, par écrouissage à au moins 25%, puis par traitement thermique. Ces nouveaux corps en alliage d'aluminium HT peuvent présenter une résistance améliorée et d'autres propriétés.
EP13757630.2A 2012-03-07 2013-02-21 Alliages d'aluminium améliorés contenant du magnésium, du silicium, du manganèse, du fer et du cuivre, et procédés de production de ceux-ci Withdrawn EP2822716A4 (fr)

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