EP4284953A1 - Alliages d'aluminium résistants à l'affaissement et à haute résistance destinés à être utilisés en tant que stock d'ailettes et leurs procédés de fabrication - Google Patents

Alliages d'aluminium résistants à l'affaissement et à haute résistance destinés à être utilisés en tant que stock d'ailettes et leurs procédés de fabrication

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Publication number
EP4284953A1
EP4284953A1 EP22701872.8A EP22701872A EP4284953A1 EP 4284953 A1 EP4284953 A1 EP 4284953A1 EP 22701872 A EP22701872 A EP 22701872A EP 4284953 A1 EP4284953 A1 EP 4284953A1
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EP
European Patent Office
Prior art keywords
aluminum alloy
mpa
alloys
aluminum
product
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.)
Pending
Application number
EP22701872.8A
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German (de)
English (en)
Inventor
Jyothi Kadali
Eider A. SIMIELLI
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.)
Novelis Inc Canada
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Novelis Inc Canada
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Publication date
Application filed by Novelis Inc Canada filed Critical Novelis Inc Canada
Publication of EP4284953A1 publication Critical patent/EP4284953A1/fr
Pending legal-status Critical Current

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Classifications

    • 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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • F28F21/081—Heat exchange elements made from metals or metal alloys
    • F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys

Definitions

  • This disclosure relates to the fields of material science, material chemistry, metallurgy, aluminum alloys, aluminum alloy products, aluminum fabrication, and related fields. More specifically, the disclosure provides novel aluminum alloys that can be used in a variety of applications, including, for example, as a fin stock for a heat exchanger.
  • the automotive heat exchanger industry presents a number of demands on the aluminum alloys used for producing heat exchanger fin stock.
  • their parts are typically joined by brazing, which requires aluminum alloys to have good brazing performance, good pre-braze mechanical properties to withstand deformation during brazing cycles, and high post-braze mechanical properties.
  • the aluminum alloys needs to be sacrificial and still have adequate corrosion properties.
  • the fin stock should also withstand slight deformation prior to brazing; therefore, the fin stock should possess good formability and strength in the as-rolled temper.
  • novel aluminum alloys that exhibit high strength and corrosion resistance.
  • the aluminum alloys described herein comprise about 0.20 - 1.30 wt. % Zn, 0.30 - 1.25 wt. % Si, 0 - 0.50 wt. % Fe, 0 - 0.20 wt. % Cu, 1.00 - 2.00 wt. % Mn, 0 - 0.10 wt. % Mg, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • the aluminum alloy comprises about 0.30 - 1.10 wt. % Zn, 0.35 - 1.20 wt.
  • the aluminum alloy comprises about 0.35 - 1.00 wt. % Zn, 0.50 - 1.10 wt. % Si, 0.05 - 0.35 wt. % Fe, 0.01 - 0.10 wt. % Cu, 1.30 - 1.70 wt.
  • the aluminum alloy comprises about 0.50 - 0.90 wt. % Zn, 0.80 - 1.10 wt. % Si, 0.05 - 0.30 wt. % Fe, 0.01 - 0.05 wt. % Cu, 1.30 - 1.50 wt. % Mn, 0.001 - 0.02 wt. % Mg, up to 0.05 wt. % Cr, up to 0.05 wt.
  • the aluminum alloy comprises about 0.75 - 0.85 wt. %, Zn, 0.80 - 0.90 wt. % Si, 0 - 0.30 wt. % Fe, 0 - 0.03 wt. % Cu, 1.35 - 1.50 wt. %, Mn, 0 - 0.05 wt. % Mg, up to 0.01 wt. % Cr, up to 0.03 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • the aluminum alloy is in an H temper.
  • the aluminum alloy has an ultimate tensile strength of the aluminum alloy is at least 140 MPa. In some aspects, the aluminum alloy has a yield strength of the aluminum alloy is at least 155 MPa. In some aspects, the aluminum alloy comprises has an electrical conductivity above 50% based on the international annealed copper standard (IACS). In some aspects, the aluminum alloy has a corrosion potential of from -700 mV to -800 mV. In some aspects, the aluminum alloy comprises 0.80 - 0.90 wt. % Si, up to 0.30 wt. % Fe, up to 0.03 wt. % Cu, 1.35 - 1.50 wt. % Mn, up to 0.05 wt. % Mg, 0.75 - 0.85 wt.
  • IACS international annealed copper standard
  • a final gauge of the aluminum alloy is less than 0.10 mm.
  • the aluminum alloy has a sag resistance less than 35 mm, when measured on a sample having a length of 35 mm.
  • a fin stock comprises any of the aluminums alloys described herein.
  • a gauge of the fin stock is 0.10 mm or less.
  • an aluminum alloy product comprises a tube and a fin, wherein the fin comprises any of the aluminums alloys described herein.
  • a method of producing an aluminum alloy product comprises casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.20 - 1.30 wt. % Zn, 0.30 - 1.25 wt. % Si, 0 - 0.50 wt. % Fe, 0 - 0.20 wt. % Cu, 1.00 - 2.00 wt. % Mn, 0 - 0.10 wt. % Mg, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, and up to 0.15 wt.
  • the method further comprises brazing the final gauge aluminum alloy product to produce a brazed aluminum alloy product.
  • the brazed aluminum alloy product has an ultimate tensile strength of at least 100 MPa, a yield strength of at least 45 MPa, and an electrical conductivity of at least 45% IACS. In some aspects, the final gauge aluminum alloy product has final gauge less than 0.10 mm. In some aspects, an aluminum alloy product is prepared by the method described herein.
  • aluminum alloy products comprising the aluminum alloys described herein.
  • the products can include a fin stock.
  • the gauge of the fin stock is 1.0 mm or less (e.g., 0.15 mm or less).
  • aluminum alloy products comprising a tube and a fin, wherein the fin comprises the aluminum alloys described herein.
  • the methods include the steps of casting an aluminum alloy as described herein to form a cast aluminum alloy, preheating the cast aluminum alloy, hot rolling the cast aluminum alloy to produce a rolled product, annealing the rolled product, and cold rolling the rolled product to a final gauge aluminum alloy product.
  • Aluminum alloy products e.g., heat exchanger fins obtained according to the methods are also provided herein.
  • Figures 1 A-1G show photographs of the particle structure for aluminum alloy samples prepared according to the present disclosure prior to brazing.
  • Figures 2A-2G show photographs of the particle structure for aluminum alloy samples prepared according to the present disclosure after brazing.
  • Figures 3A-3G show photographs of the grains for aluminum alloy samples prepared according to the present disclosure prior to brazing.
  • Figures 4A-4G show photographs of the grains for aluminum alloy samples prepared according to the present disclosure after brazing.
  • the aluminum alloys described herein exhibit improved mechanical strength, corrosion resistance, corrosion potential and/or formability compared to conventional aluminum alloys for fin stock.
  • the aluminum alloys described herein display a combination of one or more of the following properties: high pre-braze and post- braze mechanical properties (e.g., tensile strength, yield strength, elongation), sag resistance, thermal conductivity, and corrosion potential.
  • the aluminum alloys provided herein include higher amounts of Si (e.g., from about 0.3 wt. % to about 1.3 wt. %), Mn (e.g., from about 1.0 wt.
  • aluminum alloy sheets need to retain sufficient strength pre-brazing and post-brazing such that the aluminum alloy sheets do not sag.
  • the aluminum alloys described herein possess a combination of characteristics and properties that make the alloys suitable for production of heat exchanger fins, to be used, for example, in heat exchangers, such as those employed in the automotive industry.
  • the improved aluminum alloys described herein can be produced in a sheet form at desired thickness (gauge) that is suitable for production of light-weight heat exchanger fins for automotive radiators.
  • the aluminum alloys described herein can be brazed and exhibit strength characteristics before, during, and after brazing that make the alloys attractive for automotive heat exchanger applications.
  • the aluminum alloys described herein also possess sufficiently high thermal conductivity suitable for heat exchanger applications, and have a corrosion potential that is sufficiently negative for the fins to act in a sacrificial manner during corrosion of the heat exchanger.
  • the improved aluminum alloys described herein possess a combination of suitable prebraze and post-braze strength, thermal conductivity, and anodic corrosion potential values suitable for automotive fin exchanger applications.
  • the aluminum alloys described herein can be produced from input aluminum that is at least in part recycle-friendly.
  • the aluminum alloys described herein can be especially useful as a sacrificial alloy (e.g., as fin stock material for use in combination with copper or aluminum alloy tubes in heat exchangers).
  • the aluminum alloys described herein provide a material having a balance of mechanical strength as well as sacrificial alloy characteristics.
  • the aluminum alloys described herein can be formed as fin stock and attached mechanically to copper or aluminum alloy tubing. The fin stock can sacrificially corrode, thus protecting the copper or aluminum alloy tubing from corrosion.
  • alloys identified by aluminum industry designations such as “series” or “Ixxx.”
  • series or “Ixxx”
  • Ixxx alloys identified by aluminum industry designations
  • a plate generally has a thickness of greater than about 15 mm.
  • a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm.
  • a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
  • a sheet generally refers to an aluminum product having a thickness of less than about 4 mm.
  • a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.3 mm, or less than about 0.1 mm.
  • An F condition or temper refers to an aluminum alloy as fabricated.
  • An O condition or temper refers to an aluminum alloy after annealing.
  • An Hxx condition or temper also referred to herein as an H temper, refers to an aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing).
  • Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers.
  • the aluminum alloy can be strain hardened to various tempers, for example, Hl 6, Hl 8, or other HIX tempers.
  • the following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %) based on the total weight of the alloy. In certain examples of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of the impurities.
  • Electrochemical potential refers to a material’s amenability to a redox reaction. Electrochemical potential can be employed to evaluate resistance to corrosion of aluminum alloys described herein. A negative value can describe a material that is easier to oxidize (e.g., lose electrons or increase in oxidation state) when compared to a material with a positive electrochemical potential. A positive value can describe a material that is easier to reduce (e.g., gain electrons or decrease in oxidation state) when compared to a material with a negative electrochemical potential. Electrochemical potential, as used herein, is a vector quantity expressing magnitude and direction.
  • room temperature can include a temperature of from about 15° C to about 30° C, for example about 15° C, about 16° C, about 17° C, about 18° C, about 19° C, about 20° C, about 21° C, about 22° C, about 23° C, about 24° C, about 25° C, about 26° C, about 27° C, about 28° C, about 29° C, or about 30° C.
  • the alloys exhibit high pre-braze and post-braze strength, corrosion resistance, conductivity, and corrosion potential that is improved in comparison with known alloys used for fin stock production.
  • the properties of the alloys are achieved due to the elemental compositions of the alloys, and, in some cases, also the methods of processing the alloys to produce the described sheets, plates, and shates.
  • the aluminum alloys are designed to give a high pre-braze and post-braze strength without the addition of excessive amounts of solid solution strengthening elements. With the appropriate process and composition control of the main alloying additions, the resultant microstructure at final gauge exhibits a high number density of dispersoids which substantially increases the strength of the aluminum alloy.
  • the Si content decreases the solubility of Mn (e.g., from about 1.00 wt. % to about 2.00 wt. %) and promotes formation of high density dispersoids to improve pre- braze, strength, post-braze strength, and sagging resistance of the aluminum alloy.
  • Mn-containing dispersoids in solid solution increases the post-braze strength and plays an important role in controlling the sagging resistance and prevents fin erosion (e.g., liquid core penetration in the fin stock material), thus producing aluminum alloys that have an excellent combination of mechanical properties and corrosion behavior.
  • dispersoids provides additional post-braze strength through particle strengthening without compromising the electrical conductivity.
  • the Mn-containing dispersoids also control the recrystallization process during the brazing process leading to formation of large recrystallized grains.
  • the aluminum alloys described herein can tolerate higher amounts of Mg for additional solute strengthening to improve sag resistance during brazing.
  • the composition and process described herein ensure that the aluminum alloys, even when rolled to thin gauges (e.g., below 1 mm), have a high sag resistance.
  • the fin stock, tube stock and header stock materials are subject to temperatures in the range of 595° C to 610° C. At these temperatures, the aluminum components will start to creep.
  • the duration for brazing is short, the thin gauge of the aluminum alloys used and the very high temperatures make creep a particular problem for automotive fin stock. This high temperature creep is also referred to as “sag” and the ability of a material to withstand this form of creep is called sag resistance.
  • the sagging of fin stock is a combination of different mechanisms taking place at different temperatures.
  • the aluminum alloy composition described herein having a balance of alloying elements delays recrystallization of the grain structure, thus reducing the tendency to form small equiaxed grains.
  • the fine distribution of dispersoids present after casting and rolling to final gauge prevents grains growing through the sheet thickness, but allows the growth of grains in the rolling plane to form long pancake-shaped grains.
  • the delay of recrystallization and the promotion of grain growth in the rolling direction enables the aluminum alloy to develop pancake-shaped grains that provide excellent sag resistance.
  • the aluminum alloys and methods described herein can be used in industrial applications including sacrificial parts, heat dissipation, packaging, and building materials.
  • the alloys described herein can be employed as industrial fin stock for heat exchangers.
  • the industrial fin stock can be provided such that it is more resistant to corrosion than currently employed industrial fin stock alloys (e.g., AA7072 and AA1100) and will still preferentially corrode, protecting other metal parts incorporated in a heat exchanger.
  • the aluminum alloys can have the following elemental composition as provided in Table 1.
  • the aluminum alloys can have the following elemental composition as provided in Table 2.
  • the aluminum alloys can have the following elemental composition as provided in Table 3.
  • the aluminum alloys can have the following elemental composition as provided in Table 4.
  • the alloy includes zinc (Zn) in an amount from about 0.20 % to about 1.30 % (e.g., from about 0.30 % to about 1.10 %, from about 0.35 % to about 1.00 %, from about 0.50 % to about 0.90 %, or from about 0.70 % to about 0.85 %) based on the total weight of the alloy.
  • the alloy can include about 0.20 %, about 0.21 %, about 0.22 %, about 0.23 %, about 0.24 %, about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about 0.29 %, about
  • 0.68 % about 0.70 %, about 0.71 %, about 0.72 %, about 0.73 %, about 0.74 %, about 0.75 %, about 0.76 %, about 0.77 %, about 0.78 %, about 0.79 %, about 0.80 %, about 0.81 %, about 0.82 %, about 0.83 %, about 0.84 %, about 0.85 %, about 0.86 %, about 0.87 %, about 0.88 %, about 0.89 %, about 0.90 %, about 0.91 %, about 0.92 %, about 0.93 %, about 0.94 %, about 0.95 %, about 0.96 %, about 0.97 %, about 0.98 %, about 0.99 %, about 1.00 %, about 1.01 %, about 1.02 %, about 1.03 %, about 1.04 %, about 1.05 %, about 1.06 %, about 1.07 %, about 1.08 %, about 1.09 %, about 1.10 %, about 1.11
  • the Zn content can be reduced compared to conventional fin stock alloys.
  • Aluminum alloys including the claimed amount of Zn are able to act sacrificially when attached to copper or other aluminum alloy tubes, thus providing cathodic protection to the tubes.
  • Zn is known to affect the anodic potential of aluminum alloys. Zn additions will cause an aluminum alloy to become more electronegative (sacrificial).
  • the fin material is sacrificial to the tube material, which depends on the composition of the tube material itself.
  • the Zn content can improve the corrosion resistance of the aluminum alloys described herein. Specifically, when zinc is incorporated at a level as described herein, such as from about 0.20 % to about 1.30 %, the alloys exhibit enhanced corrosion resistance as compared to fin stock typically used in industrial processes (e.g., Ixxx series and 7xxx series alloys), which require a much higher content of Zn to achieve the same corrosion resistance. In some further examples, Zn can decrease resistance to corrosion when incorporated at weight percentages exceeding those described herein. In still further examples, Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin.
  • the alloys for use as fins can corrode more rapidly than for fins containing the described amount of Zn, resulting in perforations in the fin.
  • the mechanical integrity and thermal performance of the heat exchanger can be compromised, thus affecting the service life of the heat exchanger.
  • the alloy includes silicon (Si) in an amount from about 0.30 % to about 1.25 % (e.g., from about 0.35 % to about 1.20 %, from about 0.50 % to about 1.10 %, from about 0.80 % to about 1.10 %, or from about 0.80 % to about 0.90 %) based on the total weight of the alloy.
  • the alloy can include about 0.30 %, about 0.31 %, about 0.32 %, about 0.33 %, about 0.34 %, about 0.35 %, about 0.36 %, about 0.37 %, about 0.38 %, about 0.39 %, about 0.40 %, about 0.41 %, about 0.42 %, about 0.43 %, about 0.44 %, about 0.45 %, about 0.46 %, about 0.47 %, about 0.48 %, about 0.49 %, about 0.50 %, about 0.51 %, about 0.52 %, about 0.53 %, about 0.54 %, about 0.55 %, about 0.56 %, about 0.57 %, about 0.58 %, about 0.59 %, about 0.60 %, about 0.61 %, about 0.62 %, about 0.63 %, about 0.64 %, about 0.65 %, about 0.66 %, about 0.67 %, about 0.68 %, about 0.68 %, about 0.70 %, about 0.60
  • the Si content promotes formation of dispersoids to improve pre-braze and post-braze strength of the aluminum alloy, thus producing alloys that have excellent mechanical properties and corrosion potential.
  • Si combines with Mn and results in a high density of dispersoids particles which promotes high strength and good sagging resistance.
  • a high level of Si e.g. greater than 1.25 wt. %) increases the risk of fin stock erosion during brazing.
  • the alloy also includes iron (Fe) in an amount from 0 % to about 0.50 % (e.g., from 0.05 % to about 0.35 %, from 0.05 % to 0.30 %, or from 0.05 % to 0.20 %) based on the total weight of the alloy.
  • the alloy can include 0 %, about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %, about 0.05 %, about 0.60 %, about 0.07 %, about 0.08 %, about 0.09 %, about 0.10 %, about 0.11 %, about 0.12 %, about 0.13 %, about 0.14 %, about
  • a large amount of Fe e.g., greater than 0.50 wt. % can have an adverse effect on the properties of the aluminum alloy as it increases the risk forming large intermetallic constituent particles during solidification. This can lead to issues with material perforation or holes when the aluminum alloy is rolled to a final gauge.
  • the disclosed alloy includes copper (Cu) in an amount from 0 % to about 0.20 % (e.g., from 0 % to about 0.15 %, from about 0.001 % to about 0.15 %, from about 0.01 % to about 0.10 %, or from about 0.01 % to about 0.05 %) based on the total weight of the alloy.
  • Cu copper
  • the alloy can include 0 %, about, 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006 %, about 0.007 %, about 0.008 %, about 0.009 %, 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %, about 0.05 %, about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, about 0.10 %, about 0.11 %, about 0.12 %, about 0.13 %, about 0.14 %, about 0.15 %, about 0.16 %, about 0.17 %, about 0.18 %, about 0.19 %, or about 0.20 % Cu.
  • All percentages are expressed in wt. %.
  • a small addition of Cu increases the post-brazing strength and may contribute to the formation of the large pancake grains which improve the sag resistance properties.
  • a Cu content above 0.20 wt. % may lead to corrosion problems as it leads to positive corrosion potentials which is not desirable for fin stock materials.
  • the alloy can include manganese (Mn) in an amount from about 1.00 % to about 2.00% (e.g., from about 1.20 % to about 1.80 %, from about 1.30 % to about 1.70 %, or from about 1.30 % to about 1.50 %) based on the total weight of the alloy.
  • Mn manganese
  • the alloy can include about 1.00 %, about 1.01 %, about 1.02 %, about 1.03 %, about 1.04 %, about 1.05 %, about 1.06 %, about 1.07 %, about 1.08 %, about 1.09 %, about 1.10 %, about 1.11 %, about 1.12 %, about 1.13 %, about 1.14 %, about 1.15 %, about 1.16 %, about 1.17 %, about 1.18 %, about 1.19 %, about 1.20 %, about 1.21 %, about 1.22 %, about 1.23 %, about 1.24 %, about 1.25 %, about 1.26 %, about 1.27 %, about 1.28 %, about 1.29 %, about 1.30 %, about 1.31 %, about 1.32 %, about 1.33 %, about 1.34 %, about 1.35 %, about 1.36 %, about 1.37 %, about 1.38 %, about 1.39 %, about 1.40 %, about 1.
  • Mn largely remains in solid solution while a small amount is precipitated during hot rolling and interannealing as fine dispersoids.
  • the effect of this microstructure is that, when the material is heated to 600° C as in a brazing operation, the material retains strength due to the solid solution strengthening effects of the Mn.
  • Mn is optimized to provide a useful balance of properties.
  • Mn (optionally, in combination with Cu), is added to the aluminum alloy to provide strength, sagging resistance, and avoid fin erosion, but not so much to adversely affect the electrical and thermal conductivity.
  • the alloy can include magnesium (Mg) in an amount from 0 % to about 0.10 % (e.g., from 0 % to about 0.08 %, from 0 % to about 0.05 %, or from about 0.001 % to about 0.02 %) based on the total weight of the alloy.
  • Mg magnesium
  • the alloy can include 0 %, about 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006 %, about 0.007 %, about 0.008 %, about 0.009 %, about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %, about 0.05 %, about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, or about 0.10 % Mg. All percentages are expressed in wt. %.
  • the alloy includes chromium (Cr) in an amount up to about 0.10 % (e.g., from 0 % to about 0.05 %, from about 0.001 % to about 0.04 %, or from about 0.01 % to about 0.03 %) based on the total weight of the alloy.
  • Cr chromium
  • the alloy can include about 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006 %, about 0.007 %, about 0.008 %, about 0.009 %, about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %, about 0.05 %, about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, or about 0.1 % Cr. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
  • the alloy includes titanium (Ti) in an amount up to about 0.10 % (e.g., from 0 % to about 0.05 %, from about 0.001 % to about 0.04 %, or from about 0.01 % to about 0.03 %) based on the total weight of the alloy.
  • the alloy can include about 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006 %, about 0.007 %, about 0.008 %, about 0.009 %, about 0.01 %, about 0.02 %, about 0.03 %, about 0.04 %, about 0.05 %, about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, or about 0.1 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
  • the alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of about 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below each.
  • impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, Sr, or combinations thereof.
  • Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below.
  • the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.
  • exemplary aluminum alloys as described herein can include about 0.36 - 0.46 % Si, up to about 0.30 % Fe, up to about 0.02 % Cu, about 1.36 - 1.50 % Mn, up to about 0.03 % Mg, about 0.65 - 0.75 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al.
  • exemplary aluminum alloys as described herein can include about 0.36 - 0.46 % Si, up to about 0.30 % Fe, up to about 0.02 % Cu, about 1.36 - 1.50 % Mn, up to about 0.03 % Mg, about 0.95 - 1.05 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al.
  • exemplary aluminum alloys as described herein can include about 0.55 - 0.65 % Si, up to about 0.30 % Fe, up to about 0.02 % Cu, about 1.50 - 1.70 % Mn, up to about 0.03 % Mg, about 1.10 - 1.30 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al.
  • exemplary aluminum alloys as described herein can include about 0.80 - 0.90 % Si, up to about 0.30 % Fe, about 0.07 - 0.09 % Cu, about 1.25 - 1.40 % Mn, up to about 0.05 % Mg, about 0.65 - 0.75 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al.
  • exemplary aluminum alloys as described herein can include about 0.80 - 0.90 % Si, up to about 0.30 % Fe, up to about 0.03 % Cu, about 1.35 - 1.50 % Mn, up to about 0.05 % Mg, about 0.75 - 0.85 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al.
  • exemplary aluminum alloys as described herein can include about 1.00 - 1.20 % Si, up to about 0.30 % Fe, about 0.04 - 0.08 % Cu, about 1.25 - 1.40 % Mn, up to about 0.05 % Mg, about 0.95 - 1.05 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al. All percentages are expressed in wt. %.
  • an exemplary alloy includes 0.85 % Si, 0.08 % Fe, 0.014 % Cu, 1.41 % Mn, 0.002 % Mg, 0.001 % Cr, 0.81 % Zn, 0.01 % Ti, and up to 0.15 % total impurities, with the remainder as Al.
  • an exemplary alloy includes 1.10 % Si, 0.08 % Fe, 0.05 % Cu, 1.37 % Mn, 0.001 % Mg, 0.001 % Cr, 0.99 % Zn, 0.01 % Ti, and up to 0.15 % total impurities, with the remainder as Al. All percentages are expressed in wt. %.
  • HIX e.g., Hl 6 temper
  • the mechanical properties of the aluminum alloy can be controlled by various processing conditions depending on the desired use.
  • the alloy can be produced (or provided) in an H temper (e.g., HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8, or HX9 tempers).
  • HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8, or HX9 tempers As one example, the alloy can be produced (or provided) in the Hl 6 temper. It is to be understood that a particular range of properties is associated with the temper designation. It is also to be understood that the temper designation refers to the pre-braze properties of the aluminum alloy.
  • the disclosed alloys have high strength, corrosion potential, and conductivity in the H tempers (e.g., Hl 6 temper) and post-brazing.
  • the disclosed alloys have good corrosion resistance in the H tempers (e.g., Hl 6 temper) and post-braze compared to conventional 7xxx and Ixxx series aluminum alloys employed as industrial fin stock.
  • the aluminum alloy exhibits the following balance of properties. For example, the ultimate tensile strength (UTS) is greater than 100 MPa and the electrical conductivity is greater than 48% IACS after brazing at 600 °C.
  • the aluminum alloys can have a yield strength (YS) of at least about 30 MPa.
  • the yield strength is at least about 30 MPa, at least about 35 MPa, at least about 40 MPa, at least about 45 MPa, at least about 50 MPa, at least about 60 MPa, at least about 70 MPa, at least about 80 MPa, at least about 90 MPa, at least about 100 MPa, at least about 110 MPa, at least about 120 MPa, at least about 130 MPa, at least about 140 MPa, at least about 150 MPa, at least about 160 MPa, at least about 170 MPa, at least about 180 MPa, or anywhere in between.
  • the yield strength is from about 30 MPa to about 180 MPa.
  • the yield strength can be from about 35 MPa to about 170 MPa, from about 40 MPa to about 160 MPa, from about 50 MPa to about 155 MPa, from about 55 MPa to about 150 MPa, or from about 60 MPa to about 140 MPa.
  • the yield strength will vary based on the tempers of the alloys.
  • the alloys described herein provided in an H temper can have a yield strength of from at least about 100 MPa to about 170 MPa.
  • the yield strength of the alloys in H temper is at least about 110 MPa, at least about 120 MPa, at least about 125 MPa, at least about 130 MPa, at least about 135 MPa, at least about 140 MPa, at least about 145 MPa, at least about 150 MPa, at least about 155 MPa, at least about 160 MPa, at least about 165 MPa, at least about 170 MPa, or anywhere in between.
  • the alloys described herein, after brazing can have a yield strength of at least about 30 MPa, at least about 35 MPa, at least about 40 MPa, at least about 45 MPa, at least about 50 MPa, at least about 55 MPa, at least about 60 MPa, at least about 65 MPa, at least about 70 MPa, at least about 75 MPa, at least about 80 MPa, at least about 85 MPa, at least about 90 MPa, at least about 100 MPa, or anywhere in between.
  • the aluminum alloys can have an ultimate tensile strength (UTS) of at least about 70 MPa.
  • UTS ultimate tensile strength
  • the yield strength is at least about 70 MPa, at least about 80 MPa, at least about 90 MPa, at least about 100 MPa, at least about 110 MPa, at least about 120 MPa, at least about 130 MPa, at least about 140 MPa, at least about 150 MPa, at least about 160 MPa, at least about 170 MPa, at least about 180 MPa, at least about 190 MPa, at least about 200 MPa, or anywhere in between.
  • the yield strength is from about 70 MPa to about 200 MPa.
  • the yield strength can be from about 75 MPa to about 190 MPa, from about 80 MPa to about 185 MPa, from about 85 MPa to about 180 MPa, from about 90 MPa to about 175 MPa, or from about 95 MPa to about 170 MPa.
  • the alloys described herein provided in an H temper can have an UTS of from at least about 140 MPa to about 200 MPa.
  • the UTS of the alloys in H temper is at least about 140 MPa, at least about 145 MPa, at least about 150 MPa, at least about 155 MPa, at least about 160 MPa, at least about 165 MPa, at least about 170 MPa, at least about 175 MPa, at least about 180 MPa, at least about 190 MPa, at least about 200 MPa, or anywhere in between.
  • the alloys described herein provided, after brazing can have an UTS of from at least about 70 MPa to about 140 MPa.
  • the alloys described herein, after brazing can have an UTS of at least about 70 MPa, at least about 75 MPa, at least about 80 MPa, at least about 85 MPa, at least about 90 MPa, at least about 95 MPa, at least about 100 MPa, at least about 105 MPa, at least about 110 MPa, at least about 115 MPa, at least about 120 MPa, at least about 125 MPa, at least about 130 MPa, at least about 135 MPa, at least about 140 MPa, or anywhere in between.
  • the alloys described herein provided in an H temper has sufficient formability to meet an elongation of about 2 % or greater. In certain examples, the alloys described herein provided in an H temper can have an elongation of about 2 % or greater, about
  • the alloys described herein, after brazing has sufficient formability to meet an elongation of about 7 % or greater (e.g., about 9 % or greater). In certain examples, the alloys described herein, after brazing, can have an elongation of about 7 % or greater, about
  • the alloys described herein provided in an H temper can have an average conductivity value of above about 50 % based on the international annealed copper standard (IACS) (e.g., from about 50% IACS to about 60% IACS).
  • IACS international annealed copper standard
  • the alloy can have an average conductivity value of about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57 %, about 58 %, about 59 %, about 60 %, or anywhere in between. All values in % IACS.
  • the alloys described herein, after brazing can have an average conductivity value of above about 40 % based on the international annealed copper standard (IACS) (e.g., from about 40% IACS to about 55% IACS).
  • IACS international annealed copper standard
  • the alloy can have an average conductivity value of about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47 %, about 48 %, about 49 %, about 50 %, about 51%, about 52%, about 53%, about 54%, about 55%, or anywhere in between. All values in % IACS.
  • the alloys described herein can have a corrosion resistance that provides a negative corrosion potential or electrochemical potential (Ecorr) of about -700 mV or less when tested according to the ASTM G69 standard. In certain cases, an open corrosion potential value vs.
  • Standard Calomel Electrode can be about -700 mV or less, about -710 mV or less, about -720 mV or less, about -730 mV or less, about -740 mV or less, about -750 mV or less, about -760 mV or less, about -770 mV or less, about -780 mV or less, about -790 mV or less, about -800 mV or less, or anywhere in between.
  • the aluminum alloy can have an open corrosion potential of from about -700 mV to about -800 mV (e.g., from about -715 mV to about -775 mV or from about -725 mV to about -770 mV).
  • the alloys described herein have excellent sag resistance.
  • the sag resistance was measured by placing an aluminum alloy in a custom built rig including a clamping device that suspends the aluminum alloy perpendicular to the ground. Samples between about 1 inch to 2 inches wide were cut across the rolling direction and the sample length along the rolling direction was adapted to the thickness of the fin being tested. The initial height at the tip of the sample was measured. A simulated braze cycle was applied to the aluminum alloy. The distance from the tip of the brazed aluminum alloy to the ground is measured to determine the amount of deflection of the sample.
  • the alloys described herein can have an average sag distance of about 1 mm, about 1.20 mm, about 1.40 mm, about 1.60 mm, about 1.80 mm, about 2 mm, about 2.20 mm, about 2.40 mm, about 2.60 mm, about 2.80 mm, about 3 mm, about 3.20 mm, about 3.40 mm, about 3.60 mm, about 3.80 mm, about 4 mm, or anywhere in between.
  • the sagging distance may be between 0 mm to about 100 mm (e.g., less than about 35 mm) depending on the initial sample length.
  • exemplary aluminum alloys having about 0.80 - 0.90 % Si, up to about 0.30 % Fe, up to about 0.03 % Cu, about 1.35 - 1.50 % Mn, up to about 0.05 % Mg, about 0.75 - 0.85 % Zn, up to about 0.01 % Cr, up to about 0.03 % Ti, and up to about 0.15 % of impurities, and Al exhibited a pre-braze ultimate tensile strength of about 160 MPa to 180 MPa, a yield strength of about 150 MPa to 160 MPa, an elongation from 2 % to 2.50 %, and a conductivity from 55% IACS to 60% IACS.
  • the aforementioned aluminum alloy exhibited a ultimate tensile strength of about 120 MPa to 130 MPa, a yield strength of about 40 MPa to 50 MPa, an elongation from 11 % to 12%, and a conductivity from 45% IACS to 50% IACS.
  • the disclosed alloy composition is a product of a disclosed method.
  • aluminum alloy properties are partially determined by the formation of microstructures during the alloy’s preparation.
  • the method of preparation for an alloy composition may influence or even determine whether the alloy will have properties adequate for a desired application.
  • an exemplary method for producing the aluminum alloys described herein may include the following steps.
  • the method may include direct chill (DC) casting an aluminum alloy into an ingot.
  • the process comprises hot rolling of the ingot.
  • the ingots produced by casting are preheated for hot rolling.
  • the preheating temperature and duration of hot rolling are finely controlled to preserve a large grain size and high strength after the aluminum alloy is brazed.
  • the ingots can be preheated to up to about 560° C (e.g., from about 450° C to about 480° C) in a furnace at a suitable heating rate (e.g., about 60° C/hr), followed by maintaining the temperature (“soak” or “soaking”) from about 450° C to about 560° C (e.g., about 450° C to about 480° C) for about 4 hours to about 16 hours.
  • the ingots are hot rolled in the range of about 450° C to about 500° C to a thickness less from about 2 mm to about 15 mm, which may be referred to as “exit gauge” after hot rolling.
  • the aluminum alloy product is cold rolled in a two-stage cold rolling process.
  • the aluminum alloy product is cold rolled to an intermediate gauge thickness (e.g., less than about 1 mm) aluminum alloy product in a number of cold rolling passes.
  • the intermediate gauge thickness aluminum alloy product can optionally be inter-annealed at an annealing temperature from about 250° C to about 400° C (e.g., about 400° C) at a heating rate (e.g., 50° C/hr) for about 3 hours to about 5 hours.
  • the intermediate gauge thickness aluminum alloy product is cold rolled in a second cold step to produce a final gauge aluminum alloy product (e.g., about 0.05 mm to about 0.10 mm).
  • the alloy described herein can be cast using a casting method as known to those of skill in the art.
  • the casting process can include a direct chill (DC) casting process.
  • the DC casting process is performed according to standards commonly used in the aluminum industry as known to one of skill in the art.
  • the DC process can provide an ingot.
  • the ingot can be scalped before downstream processing.
  • the casting process can include a continuous casting (CC) process.
  • CC continuous casting
  • the cast aluminum alloy can then be subjected to further processing steps.
  • the processing methods as described herein can include the steps of homogenization, hot rolling, cold rolling, and/or annealing.
  • the preheating step can include heating a cast aluminum alloy as described herein to attain a preheating temperature of about, or at least about, 400° C (e.g., at least about 410° C, at least about 420° C, at least about 430° C, at least about 440° C, at least about 450° C, at least about 460° C, at least about 470° C, at least about 480° C, at least about 490° C, at least about 500° C, at least about 510° C, at least about 520° C, at least about 530° C, at least about 540° C, at least about 550° C, at least about 560° C, or anywhere in between).
  • 400° C e.g., at least about 410° C, at least about 420° C, at least about 430° C, at least about 440° C, at least about 450° C, at least about 460° C, at least about 470° C, at least about 480° C, at least about 490
  • the cast aluminum alloy can be heated to a temperature of from about 400° C to about 560° C, from about 420° C to about 550° C, from about 440° C to about 540° C, from about 450° C to about 530° C, or from about 450° C to about 480° C.
  • the heating rate to the preheating temperature can be about 10° C/hour or greater, about 20° C/hour or greater, about 30° C/hour or greater, about 40° C/hour or greater, about 50° C/hour or greater, about 60° C/hour or greater, or about 70° C/hour or greater.
  • the heating rate to the preheating temperature can be from about 10° C/min to about 100° C/min (e.g., about 10° C/min to about 90° C/min, about 20° C/min to about 80° C/min, about 30° C/min to about 70° C/min, from about 40° C/min to about 65° C/min, from about 45° C/min to about 60° C/min, or from about 50° C/min to about 60° C/min).
  • the cast aluminum alloy is then allowed to soak (i.e., held at the indicated temperature) for a period of time at the preheating temperature range.
  • the cast aluminum alloy is allowed to soak for up to about 16 hours (e.g., from about 10 minutes to about 16 hours, inclusively).
  • the cast aluminum alloy can be soaked at a temperature from about 450° C to about 560° C for about 10 minutes, about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15 hours, about 16 hours, or anywhere in between.
  • the cast aluminum alloy is soaked at a preheating temperature from about 480° C to about 560° C for about 5 hours to about 7 hours.
  • a hot rolling step can be performed.
  • the cast aluminum alloy can be hot rolled at a temperature from about 450° C to about 560° C (e.g., from about 460° C to about 550° C, from about 470° C to about 540° C, from about 480° C to about 530° C, or from about 490° C to about 520° C).
  • the hot rolling temperature is about 450° C, about 460° C, about 470° C, about 480° C, about 490° C, about 500° C, about 510° C, about 520° C, about 530° C, about 540° C, about 550° C or about 560° C.
  • the hot rolling temperature is too cold (e.g., less than 450° C), the hot roll loads are too high and may be susceptible to cracking. If the hot rolling temperature is too hot (e.g., greater than 560° C), the aluminum alloy may be too soft and break up in the hot rolling mill. In some embodiments, the cast aluminum alloy can be hot rolled at a temperature from about 450° C to about 500° C.
  • the cast aluminum alloy can be hot rolled to an about 2 mm to about 15 mm thick gauge (e.g., from about 2.5 mm to about 12 mm thick gauge).
  • the cast aluminum alloy can be hot rolled to an about 2 mm thick gauge, about 2.5 mm thick gauge, about 3 mm thick gauge, about 3.5 mm thick gauge, about 4 mm thick gauge, about 5 mm thick gauge, about 6 mm thick gauge, about 7 mm thick gauge, about 8 mm thick gauge, about 9 mm thick gauge, about 10 mm thick gauge, about 11 mm thick gauge, about 12 mm thick gauge, about 13 mm thick gauge, about 14 mm thick gauge, or about 15 mm thick gauge.
  • the cast aluminum alloy can be hot rolled to a gauge greater than 15 mm (i.e., a plate). In other cases, the cast aluminum alloy can be hot rolled to a gauge less than 4 mm (i.e., a sheet).
  • a cold rolling step can be performed.
  • the cold rolling step is a two-stage cold rolling step.
  • the two-stage cold rolling step can comprise a first cold rolling step, an optional intervening inter-annealing step, and a second cold rolling step.
  • the method can further comprise annealing the rolled product after the second cold rolling step.
  • the hot rolled products can be cold rolled to an intermediate gauge thickness in a first cold rolling step, i.e., into a first cold rolled product.
  • the hot rolled product is cold rolled to an intermediate gauge aluminum alloy product (e.g., a sheet or a shate) in the first cold rolling step.
  • the intermediate gauge aluminum alloy product has a thickness ranging from about 0.10 mm to 6 mm (e.g., from about 0.20 mm to about 5 mm, from about 0.25 mm to about 4 mm, from about 0.30 mm to about 3 mm, from about 0.40 mm to about 2 mm, from about 0.10 mm to about 1 mm, from about 0.15 mm to about 0.75 mm).
  • a second cold rolling step can be performed on the intermediate gauge aluminum alloy product.
  • the second cold rolling step can be performed after an optional interannealing step (described below).
  • the intermediate gauge aluminum alloy product is cold rolled to a final gauge aluminum alloy product (e.g., a sheet, such as a lower gauge sheet).
  • the final gauge aluminum alloy product has a thickness ranging from about 0.01 mm to 1 mm (e.g., from about 0.02 mm to about 0.90 mm, from about 0.03 mm to about 0.80 mm, from about 0.04 mm to about 0.70 mm, from about 0.05 mm to about 0.60 mm, from about 0.06 mm to about 0.50 mm, from about 0.08 mm to about 0.40 mm, from about 0.10 mm to about 0.30 mm, or from about 0.15 mm to about 0.25 mm).
  • a thickness ranging from about 0.01 mm to 1 mm (e.g., from about 0.02 mm to about 0.90 mm, from about 0.03 mm to about 0.80 mm, from about 0.04 mm to about 0.70 mm, from about 0.05 mm to about 0.60 mm, from about 0.06 mm to about 0.50 mm, from about 0.08 mm to about 0.40 mm, from about 0.10 mm to about 0.30 mm, or from about 0.15 mm
  • an optional inter-annealing step can be performed during the two-stage cold rolling step.
  • the hot rolled product can be cold rolled to an intermediate gauge aluminum alloy product (first cold rolling step), optionally coiled, annealed, and subsequently cold rolled to a final gauge aluminum alloy product (second cold rolling step).
  • first cold rolling step an intermediate gauge aluminum alloy product
  • second cold rolling step an optional inter-annealing step
  • the optional inter-annealing can be performed in a batch process (i.e., a batch inter-annealing step) or in a continuous process.
  • the inter-annealing step can be performed at a temperature of from about 250° C to about 450° C (e.g., about 250° C, about 260° C, about 270° C, about 280° C, about 290° C, about 300° C, about 310° C, about 320° C, about 330° C, about 340° C, about 350° C, about 360° C, about 370° C, about 380° C, about 390° C, about 400° C, about 410° C, about 420° C, about 430° C, about 440° C, or about 450° C).
  • about 250° C to about 450° C e.g., about 250° C, about 260° C, about 270° C, about 280° C, about 290° C, about 300° C, about 310° C, about 320° C, about 330° C, about 340° C, about 350° C, about 360° C, about 370° C, about 380° C, about 3
  • the heating rate in the inter-annealing step can be about 100° C/hour or less, 75° C/hour or less, 50° C/hour or less, 40° C/hour or less, 30° C/hour or less, 25° C/hour or less, 20° C/hour or less, or 15° C/hour or less.
  • the heating rate can be from about 10° C/min to about 100° C/min (e.g., from about 10° C/min to about 90° C/min, from about 10° C/min to about 70° C/min, from about 10° C/min to about 60° C/min, from about 20° C/min to about 90° C/min, from about 30° C/min to about 80° C/min, from about 40° C/min to about 70° C/min, or from about 50° C/min to about 60° C/min).
  • the heating rate can be from about 10° C/min to about 100° C/min (e.g., from about 10° C/min to about 90° C/min, from about 10° C/min to about 70° C/min, from about 10° C/min to about 60° C/min, from about 20° C/min to about 90° C/min, from about 30° C/min to about 80° C/min, from about 40° C/min to about 70° C/min, or from about 50° C
  • the intermediate gauge aluminum alloy product is allowed to soak for a period of time during the inter-annealing step. In some examples, the intermediate gauge aluminum alloy product is allowed to soak for up to about 5 hours (e.g., from about 30 minutes to about 4 hours, from about 45 minutes to about 3 hours, or from about 1 hour to about 2 hours, inclusively). For example, the intermediate gauge aluminum alloy product can be soaked at a temperature of from about 250° C to about 450° C for about 20 minutes, about 30 minutes, about 45 minutes, about 1 hour, about 1.5 hours, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or anywhere in between. In some examples, the intermediate gauge aluminum alloy product can be soaked at a temperature of about 400° C for about 4 hours.
  • the aluminum alloys and methods described herein can be used in industrial applications including sacrificial parts, heat dissipation, packaging, and building materials.
  • the aluminum alloys described herein can be used in various applications, for example, for manufacturing fins for heat exchangers.
  • the improved aluminum alloys described herein are useful for high performance, light weight automotive heat exchangers. More generally, the aluminum alloys described herein can be used in motor vehicle heat exchangers such as radiators, condensers and evaporators.
  • the compositions and the processes for producing the improved aluminum alloys described herein lead to a material possessing a combination of beneficial characteristics and properties that make it suitable for manufacturing heat exchanger fins.
  • the uses and applications of the improved aluminum alloys described herein are not limited to automotive heat exchangers and other uses are envisioned. It is to be understood that the characteristics and properties of the aluminum alloys described herein can also be beneficial for uses and applications other than the production of automotive heat exchanger fins.
  • the improved aluminum alloys described herein can be used for manufacture of various devices employing heat exchangers and produced by brazing, such as devices employed in heating, ventilation, and air conditioning (HVAC).
  • HVAC heating, ventilation, and air conditioning
  • the meaning of “indoor” refers to a placement contained within any structure produced by humans with controlled environmental conditions.
  • the meaning of “outdoor” refers to a placement not fully contained within any structure produced by humans and exposed to geological and meteorological environmental conditions comprising air, solar radiation, wind, rain, sleet, snow, freezing rain, ice, hail, dust storms, humidity, aridity, smoke (e.g., tobacco smoke, house fire smoke, industrial incinerator smoke and wild fire smoke), smog, fossil fuel exhaust, bio-fuel exhaust, salts (e.g., high salt content air in regions near a body of salt water), radioactivity, electromagnetic waves, corrosive gases, corrosive liquids, galvanic metals, galvanic alloys, corrosive solids, plasma, fire, electrostatic discharge (e.g., lightning), biological materials (e.g., animal waste, saliva,
  • Alloys 1, 2, 3, 4, 5, 6 are exemplary alloys produced according to methods described below.
  • Alloy A is a comparative alloy prepared according to methods described below.
  • Alloy A is a conventional aluminum alloy which is currently employed as an industrial fin stock in commercial applications.
  • Alloys 1, 2, 3, 4, 5, 6 and Alloy A were direct chill cast into ingots.
  • the ingots were preheated to 480° C at a heating rate of 60° C/h and soaked for 6 hours. After preheating, the ingots were hot rolled resulting in an aluminum alloy product having a gauge reduction from 76 mm to 2.5 mm.
  • the aluminum alloy product was cold rolled to an intermediate gauge thickness (e.g., about 0.18 mm) aluminum alloy product in five cold rolling passes.
  • the intermediate gauge thickness aluminum alloy product was interannealed at an annealing temperature of about 400° C at a heating rate of about 50° C/hr for about 4 hours.
  • the intermediate gauge thickness aluminum alloy product was cold rolled in a second cold step to produce a final gauge aluminum alloy product in an Hl 6 temper having a final gauge of 0.09 mm. Alloys 1, 2, 3, 4, 5, 6 and Alloy A were brazed using a standard brazing cycle at 600° C for 3 minutes.
  • the mechanical properties of the exemplary alloys and comparative alloy were determined according to ASTM B557. Specifically, the alloys were subjected to tensile, yield strength, elongation, and conductivity tests. The yield strength (YS), ultimate tensile strength (UTS), percent elongation (El), and percent of the International Annealed Copper Standard (% IACS) were determined. The test results are summarized in Table 6.
  • Example Alloys 4-6 exhibited excellent pre-braze strength compared to Comparative Example A currently employed as industrial fin stock.
  • Example Alloys 4-6 each exhibited a tensile strength greater than 165 MPa and a yield strength greater than 155 MPa.
  • Example Alloys 4-6 exhibited a tensile strength greater than 120 MPa and yield strength greater than 45 MPa.
  • Each of Examples Alloys 1-6 also achieved an electrical conductivity greater than 45% IACS, which was significantly greater than the electrical conductivity of Comparative Example A.
  • the exemplary alloys described herein display exceptional mechanical properties as compared to the comparative alloy and can be excellent commercial alloys employed in industrial fin stock applications.
  • the exemplary alloys exhibited electrochemical potential values comparable to electrochemical potential values of tube alloys.
  • Conventional aluminum tube alloys have an average open corrosion potential value vs. SCE of -741mV.
  • the differences between Alloys 1-6 and aluminum tube alloys ranged from 4-27 mV.
  • Comparative Alloy A had a large difference in electrochemical potential values of tube alloys.
  • the data show that Alloys 1-6 are acceptable to prepare fins that act as sacrificial anodes. Additionally, Alloys 1-6 exhibited excellent sagging resistance, while still maintaining a balance of desired mechanical and corrosion properties.
  • Figures 1 A-1G show photographs of the particle structure for Alloys 1, 2, 3, 4, 5, 6 and Alloy A prior to brazing and Figures 2A-2G show photographs of the particle structure for Alloys 1, 2, 3, 4, 5, 6 and Alloy A after brazing.
  • Alloys 1, 2, 3, 4, 5, and 6 had a high number density of dispersoids to improve pre-braze and post-braze strength and sag resistance of the aluminum alloy.
  • the carefully balanced composition of the aluminum alloys plays an important role in controlling the sag resistance. Specifically, the Si content decreases the solubility of Mn and promotes formation of high density dispersoids to improve pre-braze and post-braze strength and sagging resistance of the aluminum alloy.
  • Figures 3A-3G show photographs of the grains for Alloys 1, 2, 3, 4, 5, 6 and Alloy A prior to brazing and Figures 4A-4G show photographs of the grains for Alloys 1, 2, 3, 4, 5, 6 and Alloy A after brazing.
  • Alloys 1, 2, 3, 4, 5, and 6 each have elongated pancakeshaped grains in the rolling direction.
  • the composition of the aluminum alloys promote grain growth parallel to the rolling direction to enable the aluminum alloy to form pancake-shaped grains that provides excellent sag resistance.
  • the photographs of the grains pre-brazing and post-brazing show that 2 grains or less are formed in the rolling direction with no equiaxed grain structures.
  • the aluminum alloys described herein provide sacrificial corrosion characteristics and mechanical characteristics which enable the manufacture of aluminum alloy fin stock of reduced thickness.
  • the fin stock of reduced thickness maintains sacrificial protection for the copper or aluminum alloy tubes in contact with the fins.
  • the aluminum alloys described herein can also be used in other situations where mechanical strength in combination with sacrificial characteristics are desired.
  • Illustration 1 An aluminum alloy comprising 0.20 - 1.30 wt. % Zn, 0.30 - 1.25 wt. % Si, 0 - 0.50 wt. % Fe, 0 - 0.20 wt. % Cu, 1.00 - 2.00 wt. % Mn, 0 - 0.10 wt. % Mg, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • Illustration 2 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.30 - 1.10 wt. % Zn, 0.35 - 1.20 wt. % Si, 0.01 - 0.40 wt. % Fe, 0.001 - 0.15 wt. % Cu, 1.20 - 1.80 wt. % Mn, 0 - 0.08 wt. % Mg, up to 0.08 wt. % Cr, up to 0.08 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • Illustration 3 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.35 - 1.00 wt. % Zn, 0.50 - 1.10 wt. % Si, 0.05 - 0.35 wt. % Fe, 0.01 - 0.10 wt. % Cu, 1.30 - 1.70 wt. % Mn, 0 - 0.05 wt. % Mg, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • the aluminum alloy comprises 0.35 - 1.00 wt. % Zn, 0.50 - 1.10 wt. % Si, 0.05 - 0.35 wt. % Fe, 0.01 - 0.10 wt. % Cu, 1.30 - 1.70 wt. % Mn, 0 - 0.05 wt. % Mg, up to 0.05 wt. % Cr, up
  • Illustration 4 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.50 - 0.90 wt. % Zn, 0.80 - 1.10 wt. % Si, 0.05 - 0.30 wt. % Fe, 0.01 - 0.05 wt. % Cu, 1.30 - 1.50 wt. % Mn, 0.001 - 0.02 wt. % Mg, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • the aluminum alloy comprises 0.50 - 0.90 wt. % Zn, 0.80 - 1.10 wt. % Si, 0.05 - 0.30 wt. % Fe, 0.01 - 0.05 wt. % Cu, 1.30 - 1.50 wt. % Mn, 0.001 - 0.02 wt. % Mg, up to 0.05 wt. % Cr
  • Illustration 5 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.75 - 0.85 wt. %, Zn, 0.80 - 0.90 wt. % Si, 0 - 0.30 wt. % Fe, 0 - 0.03 wt. % Cu, 1.35 - 1.50 wt. %, Mn, 0 - 0.05 wt. % Mg, up to 0.01 wt. % Cr, up to 0.03 wt. % Ti, and up to 0.15 wt. % of impurities, and Al.
  • Illustration 6 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy is in an H temper.
  • Illustration 7 An illustration of any preceding or subsequent illustration, wherein an ultimate tensile strength of the aluminum alloy is at least 140 MPa.
  • Illustration 8 An illustration of any preceding or subsequent illustration, wherein a yield strength of the aluminum alloy is at least 155 MPa.
  • Illustration 9 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises an electrical conductivity above 50% based on the international annealed copper standard (IACS).
  • IACS international annealed copper standard
  • Illustration 10 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a corrosion potential of from -700 mV to -800 mV.
  • Illustration 11 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.80 - 0.90 wt. % Si, up to 0.30 wt. % Fe, up to 0.03 wt. % Cu, 1.35 - 1.50 wt. % Mn, up to 0.05 wt. % Mg, 0.75 - 0.85 wt. % Zn, up to 0.01 wt. % Cr, up to 0.03 wt. % Ti, up to 0.15 wt.
  • the aluminum alloy comprises 0.80 - 0.90 wt. % Si, up to 0.30 wt. % Fe, up to 0.03 wt. % Cu, 1.35 - 1.50 wt. % Mn, up to 0.05 wt. % Mg, 0.75 - 0.85 wt. % Zn, up to 0.01 wt. % Cr, up to 0.03 wt. % Ti, up to 0.15 wt.
  • the aluminum alloy has a ultimate tensile strength from 160 MPa to 180 MPa, a yield strength from 150 MPa to 160 MPa, an elongation from 2 % to 2.50 %, and a conductivity from 55% IACS to 60% IACS.
  • Illustration 12 An illustration of any preceding or subsequent illustration, wherein a final gauge of the aluminum alloy is less than 0.10 mm.
  • Illustration 13 An illustration of any preceding or subsequent illustration, wherein the aluminum alloy has a sag resistance less than 35 mm, when measured on a sample having a length of 35 mm.
  • Illustration 14 A fin stock comprising the aluminum alloy of any preceding or subsequent illustration.
  • Illustration 15 An aluminum alloy product comprising a tube and a fin, wherein the fin comprises the fin stock of any preceding or subsequent illustration.
  • Illustration 16 A method of producing an aluminum alloy product, comprising: casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.20 - 1.30 wt. % Zn, 0.30 - 1.25 wt. % Si, 0 - 0.50 wt. % Fe, 0 - 0.20 wt. % Cu, 1.00 - 2.00 wt. % Mn, 0 - 0.10 wt. % Mg, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, and up to 0.15 wt.
  • Illustration 17 An illustration of any preceding or subsequent illustration, wherein the final gauge aluminum alloy product has an ultimate tensile strength of at least 140 MPa, a yield strength of at least 155 MPa, and an electrical conductivity of at least 50% based on the international annealed copper standard (IACS).
  • IACS international annealed copper standard
  • Illustration 18 An illustration of any preceding or subsequent illustration, further comprising brazing the final gauge aluminum alloy product to produce a brazed aluminum alloy product.
  • Illustration 19 An illustration of any preceding or subsequent illustration, wherein the brazed aluminum alloy product has an ultimate tensile strength of at least 100 MPa, a yield strength of at least 45 MPa, and an electrical conductivity of at least 45% based on the international annealed copper standard (IACS).
  • IACS international annealed copper standard
  • Illustration 20 An illustration of any preceding or subsequent illustration, wherein the final gauge aluminum alloy product has final gauge less than 0.10 mm.
  • Illustration 21 An aluminum alloy is prepared by the method of any preceding or subsequent illustration.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Conductive Materials (AREA)
  • Prevention Of Electric Corrosion (AREA)
  • Extrusion Of Metal (AREA)
  • Continuous Casting (AREA)
  • Preventing Corrosion Or Incrustation Of Metals (AREA)

Abstract

L'invention concerne des alliages d'aluminium à haute résistance, résistants à la corrosion et résistants à l'affaissement, des procédés de fabrication et de traitement de tels alliages et des produits préparés à partir de tels alliages. Plus particulièrement, l'invention concerne de nouveaux alliages d'aluminium présentant une résistance mécanique, une aptitude au formage et une résistance à la corrosion améliorées. Les alliages peuvent être utilisés en tant que matière première d'ailettes dans des applications industrielles, notamment dans des échangeurs de chaleur.
EP22701872.8A 2021-02-01 2022-01-12 Alliages d'aluminium résistants à l'affaissement et à haute résistance destinés à être utilisés en tant que stock d'ailettes et leurs procédés de fabrication Pending EP4284953A1 (fr)

Applications Claiming Priority (2)

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US202163199900P 2021-02-01 2021-02-01
PCT/US2022/070150 WO2022165454A1 (fr) 2021-02-01 2022-01-12 Alliages d'aluminium résistants à l'affaissement et à haute résistance destinés à être utilisés en tant que stock d'ailettes et leurs procédés de fabrication

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EP4284953A1 true EP4284953A1 (fr) 2023-12-06

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US (1) US20240076767A1 (fr)
EP (1) EP4284953A1 (fr)
JP (1) JP2024505096A (fr)
KR (1) KR20230124698A (fr)
CN (1) CN116829749A (fr)
CA (1) CA3208151A1 (fr)
MX (1) MX2023008866A (fr)
WO (1) WO2022165454A1 (fr)

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JP5192718B2 (ja) * 2007-04-10 2013-05-08 三菱アルミニウム株式会社 強度、犠牲陽極効果、および耐食性に優れるフィン材および熱交換器
JP5925022B2 (ja) * 2012-04-06 2016-05-25 株式会社Uacj 熱交換器用アルミニウム合金フィン材、その製造方法及び熱交換器の製造方法
JP7107690B2 (ja) * 2018-01-31 2022-07-27 Ｍａアルミニウム株式会社 強度、導電性、耐食性、およびろう付性に優れる熱交換器用アルミニウム合金フィン材および熱交換器
JP7226935B2 (ja) * 2018-07-20 2023-02-21 Ｍａアルミニウム株式会社 成形性に優れた熱交換器用フィン材および熱交換器

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US20240076767A1 (en) 2024-03-07
JP2024505096A (ja) 2024-02-02
MX2023008866A (es) 2023-08-15
CA3208151A1 (fr) 2022-08-04
CN116829749A (zh) 2023-09-29
WO2022165454A1 (fr) 2022-08-04
KR20230124698A (ko) 2023-08-25

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