US20240001437A1 - Cast aluminum alloys comprising calcium and related processes - Google Patents

Cast aluminum alloys comprising calcium and related processes Download PDF

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Publication number
US20240001437A1
US20240001437A1 US18/253,708 US202218253708A US2024001437A1 US 20240001437 A1 US20240001437 A1 US 20240001437A1 US 202218253708 A US202218253708 A US 202218253708A US 2024001437 A1 US2024001437 A1 US 2024001437A1
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approximately
aluminum alloy
ppm
mpa
alloy
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Robert Bruce Wagstaff
Samuel Robert Wagstaff
Kumar Sundaram
Carlos R. Morais
Simon William Barker
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Novelis Inc Canada
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Novelis Inc Canada
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Priority to US18/253,708 priority Critical patent/US20240001437A1/en
Assigned to NOVELIS INC. reassignment NOVELIS INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MORAIS, Carlos R., WAGSTAFF, SAMUEL ROBERT, WAGSTAFF, ROBERT BRUCE, BARKER, SIMON WILLIAM, SUNDARAM, Kumar
Publication of US20240001437A1 publication Critical patent/US20240001437A1/en
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/001—Continuous casting of metals, i.e. casting in indefinite lengths of specific alloys
    • B22D11/003—Aluminium alloys
    • 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
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0221—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips characterised by the working steps
    • C21D8/0236—Cold rolling
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—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
    • C22C21/06—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
    • 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

  • the present disclosure relates to the fields of metallurgy, aluminum alloys, aluminum fabrication, and related fields.
  • the present disclosure provides cast aluminum alloy compositions which include calcium, and processes for forming the cast aluminum alloys and aluminum alloy articles.
  • Aluminum (Al) alloys are increasingly replacing steel and other metals in multiple applications, such as automotive, transportation, industrial, or electronics-related applications. In some applications, such alloys may need to exhibit high strength, high formability, corrosion resistance, and/or low weight. However, producing alloys having the aforementioned properties is a challenge, as conventional methods and compositions may not achieve the necessary requirements, specifications, and/or performances required for the different applications when produced via established methods. For example, aluminum alloys with a high solute content, including copper (Cu), magnesium (Mg), and zinc (Zn), can exhibit cracking when cast, as well as other surface imperfections.
  • Cu copper
  • Mg magnesium
  • Zn zinc
  • One known method for addressing such surface imperfections is to scalp the surface of the ingot, which involves machining off a surface layer of the ingot.
  • Another known method for addressing surface imperfections is to include beryllium in the alloy. Although beryllium was effective at controlling surface defects in aluminum cast ingots, it is no longer allowed in food or beverage packaging and is a health concern for factory workers.
  • aluminum alloys that exhibit high strength and high formability, and that do not exhibit cracking and have reduced surface defects during and/or after casting, along with methods of making and processing the alloys.
  • the alloys can be used in automotive, transportation, aerospace, industrial, and electronics applications, to name a few.
  • a process of producing an aluminum alloy product comprises continuously casting an aluminum alloy to form a slab, wherein the aluminum alloy comprises at least 2.0% by weight Mg and, in molten form, the alloy comprises from 30 ppm to 500 ppm calcium (Ca).
  • the cast slab does not exhibit cracking during and/or after casting.
  • the slab has reduced surface defects as compared to a slab without the calcium addition.
  • the aluminum alloy product can be an aluminum alloy sheet, an aluminum alloy plate, or an aluminum alloy shate, having an improved surface.
  • the surface may be viewed visually, through microscopy, to view the size and amount of exudates, as well as the shine of the surface.
  • the aluminum alloy articles prepared according to the methods herein have a more uniform surface with less open porosity than aluminum alloy articles prepared without calcium addition. Additionally, the intermetallic particles are small and well distributed.
  • the aluminum alloy product can comprise a long traverse tensile yield strength of at least 560 MPa when in a T6 temper.
  • the aluminum alloy product can comprise a bend angle of from approximately 80° to approximately 120° when in a T6 temper, such as in alloys other than 5xxx alloys.
  • the aluminum alloy product can comprise a yield strength of from approximately 500 MPa to approximately 650 MPa when in a T4 temper and after paint baking.
  • the aluminum alloy product can optionally be an automotive body part, a motor vehicle part, a transportation body part, an aerospace body part, or an electronics housing.
  • FIG. 1 is a digital image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 2 is a digital image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 3 is a digital image showing the surface of aluminum alloys according to an example described herein.
  • FIG. 4 is a micrograph image showing the surface of aluminum alloys according to an example described herein.
  • FIG. 5 is a digital image showing the surface of an aluminum alloy during processing according to an example described herein.
  • FIG. 6 is a digital image showing the surface of an aluminum alloy during processing according to an example described herein.
  • FIG. 7 is a digital image showing the surface of an aluminum alloy during processing according to an example described herein.
  • FIG. 8 is a digital image showing the surface of an aluminum alloy during processing according to an example described herein.
  • FIG. 9 is a digital image showing the surface of aluminum alloys according to an example described herein.
  • FIG. 10 is a micrograph image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 11 is a micrograph image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 12 is a composite micrograph image showing the cross-section of an aluminum alloy according to an example described herein.
  • FIG. 13 is a micrograph image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 14 is a micrograph image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 15 is a composite micrograph image showing the cross-section of an aluminum alloy according to an example described herein.
  • FIG. 16 is a micrograph image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 17 is a micrograph image showing the surface of an aluminum alloy according to an example described herein.
  • FIG. 18 is a composite micrograph image showing the cross-section of an aluminum alloy according to an example described herein.
  • FIG. 19 is an XRD of extracted particles of an aluminum alloy according to an example described herein.
  • aluminum alloys comprising magnesium wherein when the aluminum alloy is in molten form, calcium is added to the alloy prior to continuous casting.
  • aluminum alloys comprising magnesium can be difficult to cast using conventional casting processes due to their magnesium content.
  • the disclosed processes can permit the casting of aluminum alloys comprising magnesium described herein in thin gauges (e.g., aluminum alloy bodies with a thickness of from approximately 5 mm to approximately 50 mm), free from cracking during and/or after casting as determined by visual inspection (e.g., there are fewer cracks per square meter in the slab prepared according to methods described herein than in a direct chill cast ingot). Additionally, the alloys have less surface defects than those formed by processes without calcium addition. In some examples, the aluminum alloys can be continuously cast according to processes as described herein.
  • invention As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
  • metal includes pure metals, alloys and metal solid solutions unless the context clearly dictates otherwise.
  • alloys identified by aluminum industry designations such as “series” or “5xxx.”
  • series or “5xxx.”
  • a plate generally has a thickness of greater than approximately 15 mm.
  • a plate may refer to an aluminum product having a thickness of greater than approximately 15 mm, greater than approximately 20 mm, greater than approximately 25 mm, greater than approximately 30 mm, greater than approximately 35 mm, greater than approximately mm, greater than approximately 45 mm, greater than approximately 50 mm, or greater than approximately 100 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from approximately 4 mm to approximately 15 mm.
  • a shate may have a thickness of approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, approximately 10 mm, approximately 11 mm, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm.
  • a sheet generally refers to an aluminum product having a thickness of less than approximately 4 mm (e.g., less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm).
  • a sheet may have a thickness of approximately 0.1 mm, approximately 0.2 mm, approximately 0.3 mm, approximately 0.4 mm, approximately 0.5, approximately 0.6 mm, approximately 0.7 mm, approximately 0.8 mm, approximately 0.9 mm, approximately 1 mm, approximately 1.1 mm, approximately 1.2 mm, approximately 1.3 mm, approximately 1.4 mm, approximately 1.5 mm, approximately 1.6 mm, approximately 1.7 mm, approximately 1.8 mm, approximately 1.9 mm, approximately 2 mm, approximately 2.1 mm, approximately 2.2 mm, approximately 2.3 mm, approximately 2.4 mm, approximately 2.5 mm, approximately 2.6 mm, approximately 2.7 mm, approximately 2.8 mm, approximately 2.9 mm, approximately 3 mm, approximately 3.1 mm, approximately 3.2 mm, approximately 3.3 mm, approximately 3.4 mm, approximately 3.5 mm, approximately 3.6 mm, approximately 3.7 mm, approximately 3.8 mm, or approximately 3.9 mm.
  • formability refers to the ability of a material to undergo deformation into a desired shape without fracturing, tearing-off, necking, earing, or shaping errors such as wrinkling, spring-back, or galling occurring.
  • formability may be classified according to deformation modes. Examples of deformation modes include drawing, stretching, bending, and stretch-flanging.
  • 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 a non-heat treatable 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.
  • a T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature).
  • a T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged.
  • a T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged.
  • a T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged.
  • a T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures).
  • a T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged.
  • a T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged.
  • a T8 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged.
  • a T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked.
  • a W condition or temper refers to an aluminum alloy after solution heat treatment.
  • the “forming temper” refers to a temper in which the aluminum alloy can be deformed to a greater extent than a high strength temper.
  • a 6xxx series aluminum alloy can be deformed to a greater extent in a T4 temper than a T6 temper; thus, the T4 temper can be referred to as a forming temper in this example.
  • the “high strength temper” refers to a temper in which the aluminum alloy is artificially aged to peak age strength.
  • a 6xxx series aluminum alloy can be solution heat treated and artificially aged to a T6 temper to obtain a peak age strength.
  • exemplary high strength tempers can include T6, T7, T8, or T9 tempers.
  • 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.
  • Aluminum alloy properties are partially determined by the composition of the aluminum alloys.
  • the alloy composition may influence or even determine whether the alloy will have properties adequate for a desired forming application.
  • the aluminum alloy articles described herein can be made of any suitable aluminum alloy, so long as the alloy contains Mg or is modified to contain Mg, including 5xxx series aluminum alloys or 7xxx series aluminum alloys.
  • Suitable 5xxx series aluminum alloys include, for example, AA5017, AA5018, AA5018A, AA5018B, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5041, AA5052, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA54, AA5554, AA5454, AA5454A, AA5754, AA5854, AA5954,
  • Suitable 7xxx series aluminum alloys include, for example, AA7004, AA7204, AA7009, AA7010, AA7012, AA7014, AA7015, AA7017, AA7019, AA7019A, AA7022, AA7122, AA7023, AA7028, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7035, AA7035A, AA7036, AA7136, AA7037, AA7039, AA7040, AA7140, AA7041, AA7042, AA7049, AA7049A, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7055, AA7155, AA7255, AA7056, AA7060, AA7160, AA7064, AA7068, AA7168, AA7075, AA71
  • any alloy may be used so long as Mg is added to the alloy, e.g., by adding Mg to the alloy when the alloy is in molten form.
  • the aluminum alloy includes a non-heat treatable alloy.
  • the alloy can include a 1xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, or a 5xxx series aluminum alloy other than those described above.
  • the 1xxx, 3xxx, 4xxx, or 5xxx series aluminum alloys can be modified to include an amount of Mg as described above.
  • Suitable 1xxx series aluminum alloys include, for example, AA1050, AA1060, AA1070, AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, and AA1199.
  • Suitable 3xxx series aluminum alloys include, for example, AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.
  • Suitable 4xxx series aluminum alloys include, for example, AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, and AA4147.
  • the aluminum alloy includes a heat treatable alloy.
  • the alloy can include a 6xxx series aluminum alloy or a 7xxx series aluminum alloy other than those described above.
  • the 6xxx, or 7xxx series aluminum alloys can be modified to include an amount of Mg as described above.
  • Suitable 6xxx series aluminum alloys include, for example, AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA
  • the properties of the alloys can be achieved at least in part due to the elemental composition of the alloys.
  • the aluminum alloys can be heat treatable, age hardenable alloys.
  • the aluminum alloys can be aluminum alloys classified as 5xxx series aluminum alloys (e.g., wherein Mg is the predominant alloying element) or 7xxx series aluminum alloys (e.g., wherein zinc is a predominant alloying element).
  • the aluminum alloys can be modified 1xxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, or 7xxx series aluminum alloys.
  • the aluminum alloy is a 5xxx series aluminum alloy or a 7xxx series aluminum alloy comprising at least 2% by weight Mg.
  • modified as related to a series of aluminum alloys refers to an alloy composition that would typically be classified within a particular series, but the modification of one or more elements (types or amounts) results in a different predominant alloying element, e.g., magnesium.
  • the composition of an aluminum alloy may affect its response to the continuous casting processes.
  • the strength during or after continuous casting may be affected by an amount of Mg present in the alloy.
  • the articles formed by the processes described herein resulted in at least a 10% reduction in the size of exudates, e.g., at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, or at least 70%, when compared to articles formed by the same process except for the Ca addition.
  • the aluminum alloy articles described herein can be made from 1xxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, or 7xxx series aluminum alloys.
  • the alloys exhibit high strength, high formability, and corrosion resistance.
  • the aluminum alloy (as modified) includes Mg in an amount from approximately 0.3% to approximately 10%, from approximately 0.5% to approximately 10%, from approximately 0.7% to 10%, from approximately 1.0% to approximately 10%, from approximately 2.0% to approximately 10% (e.g., from 2.25% to 10%, from 2.5% to 10%, from 2.5% to 9%, from 2.5% to 8%, from 2.5% to 7.5%, or from 2.5% to 7%) based on the total weight of the alloy.
  • the alloy can include approximately 0.3%, approximately 0.4%, approximately 0.5%, approximately 0.6%, approximately 0.7%, approximately 0.8%, approximately 0.9%, approximately 1.0%, approximately 1.1%, approximately 1.2%, approximately 1.3%, approximately 1.4%, approximately 1.5%, approximately 1.6%, approximately 1.7%, approximately 1.8%, approximately 1.9%, approximately 2%, approximately 2.1%, approximately 2.2%, approximately 2.3%, approximately 2.4%, approximately 2.5%, approximately 2.6%, approximately 2.7%, approximately 2.8%, approximately 2.9%, approximately 3%, approximately 3.1%, approximately 3.2%, approximately 3.3%, approximately 3.4%, approximately 3.5%, approximately 3.6%, approximately 3.7%, approximately 3.8%, approximately 3.9%, approximately 4%, approximately 4.1%, approximately 4.2%, approximately 4.3%, approximately 4.4%, approximately 4.5%, approximately 4.6%, approximately 4.7%, approximately 4.8%, approximately 4.9%, approximately 5%, approximately 5.1%, approximately 5.2%, approximately 5.3%, approximately 5.4%, approximately 5.5%, approximately 5.6%, approximately 5.7%, approximately 5.8%, approximately 5.9%, approximately 6%, approximately 6.1%, approximately 6.2%, approximately 6.3%, approximately 6.4%,
  • the aluminum alloy includes manganese (Mn) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from % to 1%) based on the total weight of the alloy.
  • Mn manganese
  • the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Mn. In certain aspects, Mn is not present in the alloy (i.e., 0%). All expressed in wt. %.
  • the aluminum alloy includes chromium (Cr) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy.
  • Cr chromium
  • the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Cr. In certain aspects, Cr is not present in the alloy (i.e., 0%). All expressed in wt. %.
  • the aluminum alloy includes copper (Cu) in an amount from 0% to approximately 2.5% (e.g., from 0.01% to 2.25%, from 0.02% to 2%, from 0.03% to 1.5%, or from 0.04% to 1%) based on the total weight of the alloy.
  • Cu copper
  • the alloy can include 0%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, approximately 2%, approximately 2.05%, approximately 2.1, approximately 2.15%, approximately 2.2%, approximately 2.25%, approximately 2.3%, approximately 2.35%,
  • the aluminum alloy includes silicon (Si) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from % to 1%) based on the total weight of the alloy.
  • the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Si. In certain aspects, Si is not present in the alloy (i.e., 0%). All expressed in wt. %.
  • the aluminum alloy includes iron (Fe) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from % to 1%) based on the total weight of the alloy.
  • the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Fe. In certain aspects, Fe is not present in the alloy (i.e., 0%). All expressed in wt. %.
  • the aluminum alloy includes zinc (Zn) in an amount from 0% to approximately 10% (e.g., from 0.01% to 10%, from 0.05% to 9%, from 0.1% to 9%, or from 0.15% to 9%) based on the total weight of the alloy.
  • the alloy can include 0%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.1%, approximately 1.2%, approximately 1.3%, approximately 1.4%, approximately 1.5%, approximately 1.6%, approximately 1.7%, approximately 1.8%, approximately 1.9%, approximately 2%, approximately 2.1%, approximately 2.2%, approximately 2.3%, approximately 2.4%, approximately 2.5%, approximately 2.6%, approximately 2.7%, approximately 2.8%, approximately 2.9%, approximately 3%, approximately 3.1%, approximately 3.2%, approximately 3.3%, approximately 3.4%, approximately 3.5%, approximately 3.6%, approximately 3.7%, approximately 3.8%, approximately 3.9%, approximately 3%
  • the aluminum alloy includes zirconium (Zr) in an amount from 0% to approximately 0.5% (e.g., from 0% to 0.45%, from 0.01% to 0.4%, from 0.01% to 0.35%, from 0.01% to 0.2%, or from 0.02% to 0.1%) based on the total weight of the alloy.
  • Zr zirconium
  • the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, approximately 0.20%, approximately 0.21%, approximately 0.22%, approximately 0.23%, approximately 0.24%, approximately 0.25%, approximately 0.26%, approximately 0.27%, approximately 0.28%, approximately 0.29%, approximately 0.30%, approximately 0.31%, approximately 0.32%, approximately 0.33%, approximately 0.34%, approximately 0.35%, approximately 0.36%, approximately 0.37%, approximately 0.38%, approximately 0.39%, approximately 0.40%, approximately 0.001%
  • the aluminum alloy includes nickel (Ni) in an amount up to approximately 0.5% (e.g., from 0% to approximately 0.5%, from approximately 0.01% to approximately 0.4%, from approximately 0.01% to approximately 0.35%, from approximately 0.01% to approximately 0.2%, or from approximately 0.02% to approximately 0.1%) based on the total weight of the alloy.
  • Ni nickel
  • the alloy can include approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, approximately 0.20%, approximately 0.21%, approximately 0.22%, approximately 0.23%, approximately 0.24%, approximately 0.25%, approximately 0.26%, approximately 0.27%, approximately 0.28%, approximately 0.29%, approximately 0.30%, approximately 0.31%, approximately 0.32%, approximately 0.33%, approximately 0.34%, approximately 0.35%, approximately 0.36%, approximately 0.37%, approximately 0.38%, approximately 0.39%, approximately 0.40%, approximately 0.41%, approximately
  • the aluminum alloy includes tin (Sn) in an amount up to approximately 0.25% (e.g., from 0% to approximately 0.25%, from 0% to approximately 0.2%, from 0% to approximately 0.05%, from approximately 0.01% to approximately 0.15%, or from approximately 0.01% to approximately 0.1%) based on the total weight of the alloy.
  • tin (Sn) in an amount up to approximately 0.25% (e.g., from 0% to approximately 0.25%, from 0% to approximately 0.2%, from 0% to approximately 0.05%, from approximately 0.01% to approximately 0.15%, or from approximately 0.01% to approximately 0.1%) based on the total weight of the alloy.
  • the alloy can include approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, approximately 0.20%, approximately 0.21%, approximately 0.22%, approximately 0.23%, approximately 0.24%, or approximately 0.25%, Sn. All expressed in wt. %.
  • the aluminum alloy includes titanium (Ti) in an amount up to approximately 0.1% (e.g., from 0.01% to 0.1%,) based on the total weight of the alloy.
  • the alloy can include approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007% approximately 0.008%, approximately 0.009% approximately 0.01%, approximately 0.011%, approximately 0.012%, approximately 0.013%, approximately 0.014%, approximately 0.015%, approximately 0.016% approximately 0.017% approximately 0.018% approximately 0.019%, approximately 0.02%, approximately 0.021%, approximately 0.022%, approximately 0.023%, approximately 0.024%, approximately 0.025%, approximately 0.026%, approximately 0.027%, approximately 0.028%, approximately 0.029%, approximately 0.03%, approximately 0.031%, approximately 0.032%, approximately 0.033%, approximately 0.034%, approximately 0.035% approximately 0.036% approximately 0.037% approximately 0.038% approximately 0.039%, approximately 0.04%, approximately 0.05%, approximately 0.051%, approximately 0.1%, approximately
  • the aluminum alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of approximately 0.05% or below, approximately 0.04% or below, approximately 0.03% or below, approximately 0.02% or below, or approximately 0.01% or below each.
  • impurities may include, but are not limited to, V, Ga, Hf, Sr, or combinations thereof. Accordingly, V, Ga, Hf, or Sr may be present in an alloy in amounts of approximately 0.05% or below, approximately 0.04% or below, approximately 0.03% or below, approximately 0.02% or below, or approximately 0.01% or below.
  • the sum of all impurities does not exceed approximately 0.15% (e.g., approximately 0.1%). All expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.
  • the aluminum alloy may be substantially free of beryllium (Be), e.g., contains approximately 0.01% Be or below, approximately 0.009%, approximately 0.008%, approximately 0.007%, approximately 0.006%, approximately 0.005%, approximately 0.004%, approximately 0.003%, approximately 0.002%, approximately 0.001%, approximately 0.0009%, approximately 0.0008%, approximately 0.0007%, approximately 0.0006%, approximately 0.0005%, approximately 0.0004%, approximately 0.0003%, approximately 0.002%, approximately 0.0001%, or 0% Be.
  • Be beryllium
  • the aluminum alloy includes Ca in an amount up to approximately 500 ppm (e.g., from 30 ppm to 500 ppm, from 40 ppm to 500 ppm, from 50 ppm to 500 ppm, from 50 ppm to 400 ppm, or from 50 ppm to 250 ppm) based on the total weight of the alloy.
  • 500 ppm e.g., from 30 ppm to 500 ppm, from 40 ppm to 500 ppm, from 50 ppm to 500 ppm, from 50 ppm to 400 ppm, or from 50 ppm to 250 ppm
  • the alloy can include approximately 30 ppm, approximately 35 ppm, approximately 40 ppm, approximately 45 ppm, approximately 50 ppm, approximately 55 ppm, approximately 60 ppm, approximately 65 ppm, approximately 70 ppm, approximately 75 ppm, approximately 80 ppm, approximately 85 ppm, approximately 90 ppm, approximately 95 ppm, approximately 100 ppm, approximately 105 ppm, approximately 110 ppm, approximately 115 ppm, approximately 120 ppm, approximately 125 ppm, approximately 130 ppm, approximately 135 ppm, approximately 140 ppm, approximately 145 ppm, approximately 150 ppm, approximately 155 ppm, approximately 160 ppm, approximately 165 ppm, approximately 170 ppm, approximately 175 ppm, approximately 180 ppm, approximately 185 ppm, approximately 190 ppm, approximately 195 ppm, approximately 200 ppm, approximately 205 ppm, approximately 210 ppm, approximately 215 ppm, approximately 220 ppm,
  • the aluminum alloy can be cast and then further processing steps may be performed.
  • the processing steps include an optional quenching step, a pre-heating and/or a homogenizing step, a hot rolling step, a solutionizing step, an artificial aging step, an optional coating step and an optional paint baking step.
  • the method comprises casting a slab; hot rolling the slab to produce a hot rolled aluminum alloy in a form of a sheet, shate or plate; solutionizing the aluminum sheet, shate or plate; and aging the aluminum sheet, shate or plate.
  • the slabs are thermally quenched upon exit from the continuous caster.
  • the slabs are coiled upon exit from the continuous caster.
  • the coiled slabs are cooled in air.
  • the method further includes preheating the coiled slabs.
  • the method further includes coating the aged aluminum sheet, shate, or plate.
  • the method further includes paint baking the coated aluminum sheet, shate, or plate. The method steps are further described below.
  • the alloys described herein can be cast into slabs using a continuous casting (CC) process.
  • CC continuous casting
  • the aluminum alloy is melted and when in molten form, Ca is added to the alloy.
  • Mg may also be added to the alloy in molten form. In some aspects, the Mg is added within 5 hours of casting to reduce oxidation of the Mg.
  • the Ca may be added to the molten alloy at any point of the process prior to casting, including when feeding the molten alloy to the casting device, i.e., in the trough.
  • the continuous casting device can be any suitable continuous casting device.
  • the continuous casting process can include, but is not limited to, the use of block casters, twin roll casters or twin belt casters.
  • the continuous casting can be performed at rates up to approximately 35 meters/minute (m/min).
  • the resulting cast aluminum alloy can have a thickness of approximately 1 mm to approximately 50 mm (e.g., from approximately 10 mm to approximately 45 mm, from approximately 15 mm to approximately 40 mm, or from approximately 20 mm to approximately 35 mm), such as approximately 10 mm.
  • the resulting slab can be 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, 41 mm, 42 mm, 43 mm, 44 mm, 45 mm, 46 mm, 47 mm, 48 mm, 49 mm, or 50 mm thick.
  • the resulting slabs can optionally be thermally quenched upon exit from the continuous caster.
  • the quench is performed with water.
  • the water quenching step can be performed at a rate of up to approximately 200° C./s (for example, from 10° C./s to 190° C./s, from 25° C./s to 175° C./s, from 50° C./s to 150° C./s, from 75° C./s to 125° C./s, or from 10° C./s to 50° C./s).
  • the water temperature can be from approximately 20° C. to approximately 75° C.
  • the resulting slabs can be coiled upon exit from the continuous caster.
  • the resulting intermediate coil can be cooled in air.
  • the air cooling step can be performed at a rate of approximately 1° C./s to approximately 300° C./day.
  • water quenching the slab upon exit from the continuous caster results in an aluminum alloy slab in a T4-temper condition.
  • the slab in T4-temper can then be optionally coiled into an intermediate coil and stored for a time period of up to 24 hours.
  • the defect count and the formation of exudates is decreased as compared to continuously cast slabs without the addition of the above described amounts of Ca.
  • the cast aluminum alloy comprises an improved surface, as quantified by number or exudates, exudate size, and/or “streaks” in the article.
  • the oxide layer thickness may be quantified using Scanning Electron microscopy by comparing the Al—O ratio to standards of known oxide thickness. Direct measurement by Transmission Electron microscopy may also be viable.
  • the Ca addition may also help the slab to self-repair of the oxide, such as during hot rolling.
  • the slab can be coiled into an intermediate coil upon exit from the continuous caster.
  • the slab is coiled into an intermediate coil upon exit from the continuous caster resulting in F-temper.
  • the coil is cooled in air.
  • the air cooled coil is stored for a period of time.
  • the intermediate coils are maintained at a temperature of approximately 100° C. to approximately 350° C. (for example, approximately 200° C. or approximately 300° C.).
  • the intermediate coils are maintained in cold storage to prevent natural aging resulting in F-temper.
  • the intermediate coils can be optionally reheated in a pre-heating step.
  • the reheating step can include pre-heating the intermediate coils for a hot rolling step.
  • the reheating step can include pre-heating the intermediate coils at a rate of up to approximately 150° C./h (for example, approximately 10° C./h or approximately 50° C./h).
  • the intermediate coils can be heated to a temperature of approximately 350° C. to approximately 580° C. (e.g., approximately 375° C. to approximately 570° C., approximately 400° C. to approximately 550° C., approximately 425° C. to approximately 500° C., or approximately 500° C. to approximately 580° C.).
  • the intermediate coils can soak for approximately 1 minute to approximately 120 minutes, preferably approximately 60 minutes.
  • the intermediate coils after storage and/or pre-heating of the coils or the slab upon exit from the caster can be homogenized.
  • the homogenization step can include heating the slab or intermediate coil to attain a peak metal temperature (PMT) of about, or at least about, 450° C. (e.g., at least 460° C., at least 470° C., at least 480° C., at least 490° C., at least 500° C., at least 510° C., at least 520° C., at least 530° C., at least 540° C., at least 550° C., at least 560° C., at least 570° C., or at least 580° C.).
  • PMT peak metal temperature
  • the cast aluminum alloy product can be heated to a temperature of from about 450° C. to about 580° C., from about 460° C. to about 575° C., from about 470° C. to about 570° C., from about 480° C. to about 565° C., from about 490° C. to about 555° C., or from about 500° C. to about 550° C.
  • the heating rate to the PMT can be about 100° C./hour or less, 75° C./hour or less, 50° C./hour or less, 40 5° 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 to the PMT 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 to the PMT 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
  • the cast aluminum alloy product is then allowed to soak (i.e., held at the indicated temperature) for a period of time.
  • the cast aluminum alloy product is allowed to soak for at least 30 minutes at a peak metal temperature as described above.
  • the cast aluminum alloy product is allowed to soak for up to about 36 hours (e.g., from about 30 minutes to about 36 hours, inclusively).
  • the cast aluminum alloy product can be soaked at the peak metal temperature for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours, 26 hours, 27 hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours, 35 hours, 36 hours, or anywhere in between.
  • a hot rolling step can be performed.
  • the hot rolling step can include a hot reversing mill operation and/or a hot tandem mill operation.
  • the hot rolling step can be performed at a temperature ranging from about 250° C. to about 550° C. (e.g., from about 300° C. to about 500° C. or from about 350° C. to about 450° C.).
  • the cast aluminum alloy product can be hot rolled to an about 4 mm to about 15 mm thick gauge (e.g., from about 5 mm to about 12 mm thick gauge), which is referred to as a shate.
  • the cast aluminum alloy product can be hot rolled to an 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 product can be hot rolled to a gauge greater than 15 mm thick (i.e., a plate).
  • the cast aluminum alloy product can be hot rolled to a gauge less than 4 mm (i.e., a sheet).
  • the hot rolled product can be rolled up as a coil.
  • the coiling temperature can be at least 285° C. and may range from about 285° C. to about 450° C. (e.g., from about 285° C. to about 400° C., from about 285° C. to about 350° C., from about 300° C. to about 350° C. or from about 310° C. to about 330° C.).
  • a cold rolling step can optionally be applied to the alloy to form a final gauge product.
  • the cast aluminum alloy product can be cold rolled to a thickness of less than about 4 mm.
  • a sheet may have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.
  • the temper of the as-rolled sheets is referred to as F-temper.
  • the process described herein can optionally include at least one deforming step applied to the final gauge product.
  • deforming includes cutting, stamping, pressing, press-forming, drawing, shaping, straining or other processes that can create two- or three-dimensional shapes as known to one of ordinary skill in the art.
  • the deforming step can be performed on an aluminum alloy sheet, plate, or shate that has a temperature of about room temperature (e.g., from about 15° C. to about 30° C.) (referred to as cold forming) or that has been heated to an elevated temperature (referred to as a warm forming process or a hot forming process).
  • a warm forming procedure can be applied to form an aluminum alloy product.
  • the warm forming can include heating the aluminum alloy product to a temperature of about 40° C. to less than about 100° C.
  • a hot forming procedure can be applied to form an aluminum alloy article.
  • the hot forming can include heating the aluminum alloy product to temperatures of about 100° C. to about 600° C. at a heating rate of about 3° C./second to about 90° C./second, deforming the aluminum alloy product to form an aluminum alloy article, optionally repeating the deforming step and cooling the article.
  • a cryogenic forming procedure can be applied to form an aluminum alloy product.
  • the cryogenic forming can include cooling the aluminum alloy product to a temperature of about 0° C. to about ⁇ 200° C.
  • the hot rolled metal is subjected to an artificial aging step.
  • the artificial aging step develops the high strength property of the alloys and optimizes other desirable properties in the alloys.
  • the mechanical properties of the final product can be controlled by various aging conditions depending on the desired use.
  • the metal product described herein can be delivered to customers in a Tx temper (a T1 temper, a T4 temper, a T5 temper, a T6 temper, a T7 temper, or a T8 temper, for example), a W temper, an O temper, or an F temper.
  • an artificial aging step can be performed.
  • the artificial aging step can be performed at a temperature from approximately 100° C. to approximately 140° C. (e.g., at approximately 120° C.
  • the artificial aging step can be performed for a period of time from approximately 12 hours to approximately 36 hours (e.g., for approximately 18 hours or for approximately 24 hours). In some examples, the artificial aging step can be performed at 125° C. for 24 hours to result in a T6 temper. In some still further examples, the alloys are subjected to a natural aging step. The natural aging step can result in a T4 temper.
  • the yield strength can be approximately 400 MPa, 410 MPa, 420 MPa, 430 MPa, 440 MPa, 450 MPa, 460 MPa, 470 MPa, 480 MPa, 490 MPa, 500 MPa, 510 MPa, 520 MPa, 530 MPa, 540 MPa, 550 MPa, 560 MPa, 570 MPa, 580 MPa, 590 MPa, 600 MPa, 610 MPa, 620 MPa, 630 MPa, 640 MPa, or 650 MPa.
  • the metal product having a yield strength of from approximately 400 MPa to 650 MPa can be in the T6 temper.
  • the resulting metal product has a maximum yield strength of from approximately 560 MPa to 650 MPa.
  • the maximum yield strength of the metal product can be approximately 560 MPa, 570 MPa, 580 MPa, 590 MPa, 600 MPa, 610 MPa, 620 MPa, 630 MPa, 640 MPa, or 650 MPa.
  • the metal product having a maximum yield strength of from approximately 560 MPa to 650 MPa can be in the T6 temper.
  • the metal product can have a yield strength of from approximately 500 MPa to approximately 650 MPa after paint baking the metal product in the T4 temper (i.e., without any artificial aging).
  • the yield strength may be at least 100 MPA and in the H19 temper, the yield strength may be at least 300 MPa.
  • the resulting metal product has an ultimate tensile strength of from approximately 500 MPa to 650 MPa (e.g., from 550 MPa to 625 MPa or from 575 MPa to 600 MPa).
  • the ultimate tensile strength can be approximately 500 MPa, 510 MPa, 520 MPa, 530 MPa, 540 MPa, 550 MPa, 560 MPa, 570 MPa, 580 MPa, 590 MPa, 600 MPa, 610 MPa, 620 MPa, 630 MPa, 640 MPa, or 650 MPa.
  • the metal product having an ultimate tensile strength of from approximately 500 MPa to 650 MPa is in the T6 temper.
  • the resulting metal product has an interior bend angle of from approximately 1000 to 1600 (e.g., from approximately 1100 to 1550 or from approximately 1200 to 150°).
  • the bend angle of the resulting metal product can be approximately 100°, 101°, 102°, 103°, 104°, 105°, 106°, 107°, 108°, 109°, 110°, 111°, 112°, 113°, 114°, 115°, 116°, 117°, 118°, 119°, 120°, 121°, 122°, 123°, 124°, 125°, 126°, 127°, 128°, 129°, 130°, 131°, 132°, 133°, 134°, 135°, 136°, 137°, 138°, 139°, 140°, 141°, 142°, 143°, 144°, 145°, 146°, 147°, 148°, 149°, 150°,
  • Sample A was a control, with no Ca addition (8 ppm Ca was present in the alloy), while in Sample B, Ca was added. Similarly, Samples C and E were controls while Sample D had Ca added. Each sample had a gauge of 12.6 mm. Samples A-B were cast at a speed of 3 m/min and Samples C-E were cast at 4 m/min. Samples AA, BB, and CC were prepared as described above and were cast as 3 m/min. Sample AA had 36 ppm Ca, and Samples BB and CC were prepared by using the composition of Sample AA and then adding Ca to provide samples with 72 ppm Ca, and 199 ppm Ca, respectively. The Ca was added by adding a short piece of Ca containing rod at specified intervals until the desired Ca concentration was reached.
  • FIG. 1 A photograph of Sample A is shown in FIG. 1 and a photograph of Sample B is shown in FIG. 2 .
  • Sample A had a shinier surface than Sample B, indicating a positive effect from Ca addition.
  • Photographs of Samples C-E are shown in FIG. 3 .
  • FIG. 3 the exudates appeared smaller with Ca addition.
  • FIG. 4 shows a zoomed in photograph of Samples C and D, with Sample C shown on the left and Sample D shown on the right. Sample D had more uniform porosity associated with the exudates and had smaller exudates. The intermetallic particles were small in both Samples C and D, though smaller in Sample D.
  • FIG. 10 shows a number of pores 1010 which were formed due to a lack of proper degassing.
  • FIG. 11 shows the presence of Fe-IMCs in the AA5182 aluminum alloy.
  • FIG. 12 is a cross-sectional composite view of the AA5182 aluminum alloy.
  • FIG. 12 shows that the pores 1010 formed throughout the bulk of the AA5182 aluminum alloy, due to a lack of proper degassing.
  • Samples F, H, I, J and L were controls, with no Ca addition (6-7 ppm Ca was present in the alloy), while in Samples G and K, Ca was added as described in Example 1 above. Each sample had a gauge of 12.6 mm. Samples F-I were cast at a speed of 3 m/min and Samples J-L were cast at a speed of 4 m/min.
  • Sample F was produced having a hydrogen content of 0.16 ppm
  • Sample G was produced having a hydrogen content of 0.22 ppm
  • Sample H was produced having a hydrogen content of 0.19 ppm
  • Sample I was produced having a hydrogen content of 0.30 ppm.
  • Samples J-L were produced having the same hydrogen content.
  • Samples DD and EE were prepared as described above, including 36 ppm Ca and 72 ppm Ca, respectively.
  • Intermetallic particle content including dendritic ⁇ -Al(FeMn)Si, platelet ⁇ -AlFeSi, Q-Al 5 Cu 2 MgsSi 6 (e.g., Fe-IMCs), and Al 2 Cu, was evaluated with respect to Ca content.
  • the pores 1010 that formed as shown in FIG. 13 were due to a lack of proper degassing.
  • FIG. 14 shows the presence of Fe-IMCs and Al 2 Cu in the X615 aluminum alloy. Additionally, FIG. 15 is a cross-sectional composite view of the X615 aluminum alloy.
  • FIG. 15 shows that the pores 1010 formed throughout the bulk of the X615 aluminum alloy, due to a lack of proper degassing. As shown in FIG. 15 , larger Fe-IMCs formed near the center of the bulk of the X615 aluminum alloy, which is attributed to centerline segregation occurring while producing the X615 aluminum alloy.
  • Samples FF and GG were prepared as described above, including 29 ppm Ca and then addition of Ca so that Sample GG had 107 ppm Ca.
  • Intermetallic particle content including ⁇ -Al(FeMn)Si, Al 6 FeMn (e.g., Fe-IMCs), and Mg 2 Si, was evaluated with respect to Ca content.
  • Ca addition in Sample GG increased the amount of ⁇ -Al(FeMn)Si allowed to form and decreased the amount of Al 6 FeMn allowed to form, as shown in FIG. 19 .
  • the relative proportion of intermetallic phases in the extracted particles, quantified using XRD is shown below.
  • Illustration 1 is a process for casting an aluminum alloy, comprising: melting an aluminum alloy to form a molten aluminum alloy, wherein the molten aluminum alloy comprises Mg; adding at least 30 ppm Ca to the molten aluminum alloy; and continuously casting the molten aluminum alloy to form a cast aluminum alloy.
  • Illustration 2 is the process of any preceding or subsequent illustration, wherein the aluminum alloy does not comprise Mg, and wherein the process further comprises adding Mg to the molten aluminum alloy.
  • Illustration 3 is the process of any preceding or subsequent illustration, wherein the aluminum alloy article is a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.
  • Illustration 4 is the process of any preceding or subsequent illustration, wherein the Ca is added to the molten aluminum alloy in an amount from 50 ppm to 500 ppm.
  • Illustration 5 is the process of any preceding or subsequent illustration, wherein the Ca is added to the molten aluminum alloy in an amount from 50 ppm to 400 ppm.
  • Illustration 6 is the process of any preceding or subsequent illustration, wherein the Ca is added to the molten aluminum alloy in an amount from 50 ppm to 250 ppm.
  • Illustration 7 is the process of any preceding or subsequent illustration, wherein the Ca is added to the molten aluminum alloy in a trough of a continuous caster.
  • Illustration 8 is the process of any preceding or subsequent illustration, wherein the molten aluminum alloy is substantially free of Be.
  • Illustration 9 is the process of any preceding or subsequent illustration, wherein the cast aluminum alloy comprises at least 0.3% by weight Mg.
  • Illustration 10 is the process of any preceding or subsequent illustration, wherein the cast aluminum alloy comprises an oxide surface layer.
  • Illustration 11 is the process of any preceding or subsequent illustration, further comprising cooling the cast aluminum alloy upon exit from a continuous caster.
  • Illustration 12 is the process of any preceding or subsequent illustration, wherein the cooling step comprises water quenching the cast aluminum alloy.
  • Illustration 13 is the process of any preceding or subsequent illustration, wherein the cast aluminum alloy is coiled.
  • Illustration 14 is the process of any preceding or subsequent illustration, further comprising: solutionizing the aluminum alloy article; quenching the aluminum alloy article; and aging the aluminum alloy article.
  • Illustration 15 is the process of any preceding or subsequent illustration, wherein a cold rolling step is performed.
  • Illustration 16 is an aluminum alloy article prepared according to the process of any preceding or subsequent illustration.
  • Illustration 18 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy article is an automotive body part, a motor vehicle part, a transportation body part, an aerospace body part, or an electronics housing.

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  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Continuous Casting (AREA)
  • Forging (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
US18/253,708 2021-01-26 2022-01-26 Cast aluminum alloys comprising calcium and related processes Pending US20240001437A1 (en)

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US18/253,708 US20240001437A1 (en) 2021-01-26 2022-01-26 Cast aluminum alloys comprising calcium and related processes
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EP (1) EP4284956A1 (ja)
JP (1) JP2024504029A (ja)
KR (1) KR20230095109A (ja)
CN (1) CN116583613A (ja)
CA (1) CA3204304A1 (ja)
MX (1) MX2023008566A (ja)
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US6412164B1 (en) * 2000-10-10 2002-07-02 Alcoa Inc. Aluminum alloys having improved cast surface quality
KR20120038008A (ko) * 2009-07-24 2012-04-20 알코아 인코포레이티드 개선된 5ｘｘｘ 알루미늄 합금 및 이로부터 제조된 단조된 알루미늄 합금 제품
WO2020172046A1 (en) * 2019-02-20 2020-08-27 Howmet Aerospace Inc. Improved aluminum-magnesium-zinc aluminum alloys

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EP4284956A1 (en) 2023-12-06
JP2024504029A (ja) 2024-01-30
CN116583613A (zh) 2023-08-11
WO2022165492A1 (en) 2022-08-04
MX2023008566A (es) 2023-08-08
CA3204304A1 (en) 2022-08-04

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