Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D51/00—Making hollow objects
  • B21D51/16—Making hollow objects characterised by the use of the objects
  • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
  • B21D22/20—Deep-drawing
  • B21D22/28—Deep-drawing of cylindrical articles using consecutive dies
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
  • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
  • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
  • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F3/00—Changing the physical structure of non-ferrous metals or alloys by special physical methods, e.g. treatment with neutrons

Definitions

• the present disclosure is directed to aluminum alloy products and their properties.
• the disclosure further relates to can body stock, can end stock, and methods of producing and processing the same.
• Metal cans are well known and widely used as beverage containers. Beverage can bodies are manufactured at high production rates and there is an ever-increasing demand to further increase the production rate of beverage cans by eliminating metal- related jams at the cupper press, as well as tear-offs and split domes at the bodymakers.
• existing aluminum can body stock can cause a reduction in productivity rates for can body production when tension and friction forces are not balanced during the can body production process.
• the inherent formability properties of existing anisotropic aluminum can end stock can cause draw-off due to uneven friction forces.
• aluminum alloy products having two different surface roughnesses for use as can body sheet are disclosed herein.
• the aluminum alloy products can have at least two surfaces, each independently having an average surface roughness that may be abbreviated as Ra.
• the aluminum alloy products in these examples comprise a first surface having a first average surface roughness and a second surface having a second average surface roughness, wherein the first average surface roughness is at least 20 % lower than the second average surface roughness, as measured by a surface profilometer.
• the first average surface roughness is less than 0.4 pm.
• the second average surface roughness is greater than or equal to 0.4 pm.
• the aluminum alloy is a 3xxx series aluminum alloy, such as an AA3104 aluminum alloy.
• the aluminum alloy comprises about 0.05 - 0.25 wt. % Cu, up to about 0.8 wt. % Fe, about 0.8 - 1.3 wt. % Mg, about 0.8 - 1.4 wt. % Mn, up to about 0.6 wt. % Si, up to about 0.1 wt. % Ti, up to about 0.25 wt. % Zn, up to about 0.05 wt. % impurities, and Al.
• the aluminum alloy product has a thickness of less than about 4 millimeters (mm).
• methods of making a can body from the can body sheet described above are disclosed herein.
• the methods of making a can body include contacting the sheet aluminum alloy product with a cupping press to form a cup.
• the cup comprises a cup inner surface having a cup inner surface average surface roughness and a cup outer surface having a cup outer surface average surface roughness, wherein the cup inner surface average surface roughness is greater than the cup outer surface average surface roughness.
• the method of making also includes the steps of contacting the cup inner surface with a punch sleeve and contacting the cup outer surface with an ironing die and ironing the cup to a desired height.
• the methods further include trimming the walls to form the can body.
• the cup has an outer surface average surface roughness Ra (referred to herein as a cup outer surface average surface roughness) that is less than 0.4 pm. In some examples, the cup has an inner surface average surface roughness Ra (referred to herein as a cup inner surface average surface roughness) that is greater than or equal to 0.4 pm. In some instances, the can body has an inner surface having a can body inner surface average surface roughness and an outer surface having a can body outer surface average surface roughness, wherein the can body inner surface average surface roughness is at least 10 % greater than the can body outer surface average surface roughness.
• aluminum alloy products for use as can end sheet are disclosed herein.
• the can end sheet has a surface percent isotropy of greater than 80 % as measured by confocal microscopy, and has a formability distortion of less than 10 %.
• the aluminum alloy product has an isotropy of greater than 95 %.
• the aluminum alloy is a 5xxx series aluminum alloy, for example, a 5182 aluminum alloy.
• the aluminum alloy product has a Texture Aspect Ratio (Str) value of greater than 0.7, according to ISO 25178.
• Figure 1 is a schematic drawing of an aluminum alloy cup according to some examples.
• Figure 2 is a schematic drawing of a cross section of an aluminum alloy product according to some examples.
• Figure 3 is a schematic drawing of a stamped can end according to some examples.
• Described herein are aluminum alloys with improved formability, aluminum alloy products, and methods for making the products.
• the aluminum alloy compositions and methods described herein provide improved aluminum alloy sheets for the efficient production of aluminum alloy products, such as aluminum can bodies having two different surface roughnesses and can ends having decreased anisotropy.
• 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.
• the term foil indicates an alloy thickness in a range of up to about 0.2 mm (i.e., 200 microns (pm)).
• a foil may have a thickness of up to 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 110 pm, 120 pm, 130 pm, 140 pm, 150 pm, 160 pm, 170 pm, 180 pm, 190 pm, or 200 pm.
• the aluminum alloys herein 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.
• the aluminum alloy product can be a sheet that has a substantially planar shape with at least two surfaces, such as a top surface and a bottom surface. “Substantially” planar, for purposes of this application, means having a measurement in the z-axis that is no more than 50 %, no more than 40 % , no more than 30 % , no more than 20 % , no more than 10 % , no more than 5 % ,or no more than 1 % of the measurement in either the x axis or the y axis.
• a sheet that is substantially could have measurements of 1 meter in the x-axis, 1000 meters in the y-axis, and 1 millimeter in the z-axis.
• the aluminum alloy product is a can body sheet.
• the top and bottom surfaces of the aluminum alloy product can have different surface roughnesses Ra, such as a first surface having a first average surface roughness and a second surface having a second average surface roughness.
• the first average surface roughness is at least 20 % lower than the second average surface roughness.
• the first average surface roughness is at least 21 % lower, at least 22 % lower, at least 23 % lower, at least 24 % lower, at least 25 % lower, at least 26 % lower, at least 27 % lower, at least 28 % lower, at least 29 % lower, at least 30 % lower, at least 35 % lower, at least 40 % lower, at least 45 % lower, at least 50 % lower, at least 55 % lower, at least 50 % lower, at least 65 % lower, at least 70 % lower, at least 75 % lower, at least 80 % lower, at least 85 % lower, at least 90 % lower, or at least 95 % lower than the second average surface roughness.
• the maximum surface roughness Ra value of the first surface would be 0.80 pm when the first average surface roughness is at least 20 % lower than the second average surface roughness.
• Surface roughness may be measured by any method known in the art.
• a surface profilometer is used to measure and describe the surface features, which is reported as “average surface roughness.”
• the term average surface roughness is used for purposes herein to convey that the surface features may be regular and repeating in a consistent manner, like the surface features of an egg carton, or irregular and not repeating in a consistent manner, like the surface of a mountain range.
• the “average surface roughness” measures and reports the average distance from a plane.
• a two dimensional (2D) or a three dimensional (3D) profilometer may be used to determine average surface roughness.
• the profilometer employs a stylus to measure average surface roughness; in other cases, optical methods may be used.
• the average surface roughness is measured by confocal microscopy.
• the surfaces are characterized herein by various parameters, including Ra and Rz, which are measured in micrometers (microns) and are known to those of skill in the art.
• the parameters can be measured using the MountainsMap® Surface Imaging and Metrology software (Digital Surf; Besancon, France). All roughness values can be mechanically measured with a standard stylus.
• the average surface roughness is measured and reported as Str according to ISO 25178 [2019]
• the Str value is the ratio of the shortest wavelength to the longest wavelength measured in any direction relative to the rolling direction.
• a can body sheet is subjected to two-piece drawing and wall ironing.
• the can body sheet is first contacted with a cupping press to form a cup, and then the cup is transferred to a punch sleeve for drawing and ironing.
• the cup 10 has an inner surface 11 and an outer surface 12.
• the materials and methods disclosed herein have the advantages of reducing can body fractures and also reducing the amount of lubricant.
• the materials and methods are described in some instances regarding can body sheet, a person of ordinary skill will understand that the materials and methods are applicable to any aluminum alloy product that is punched, stamped, drawn and/or ironed, when it would be beneficial to increase friction between a machine component and a surface of an aluminum alloy product.
• the aluminum alloy product can be a shate, a sheet, or a foil.
• the average surface roughnesses required to balance tension and friction, as well as the difference between the two average surface roughnesses required may vary according to the particular design of the punch sleeves and the ironing dies and the particular aluminum alloy product.
• the first surface which may correspond to the outer surface 12 of the cup 10
• the second surface which may correspond to the inner surface 11 of the cup 10.
• the first average surface roughness Ra of the first surface is lower than the second average surface roughness Ra of the second surface.
• a smoother surface will have fewer and/or smaller topographical features such as bumps, ridges, lines, and/or projections than a rougher surface.
• the first average surface roughness Ra is less than 0.4 pm.
• the first average surface roughness Ra is less than 0.38 pm, less than 0.36 pm, less than 0.34 pm, less than 0.32 pm, less than 0.28 pm, less than 0.26 pm, less than 0.24 pm, less than 0.22 pm, less than 0.2 pm, less than 0.18 pm, less than 0.16 pm, less than 0.14 pm, less than 0.12 pm, less than 0.1 pm, less than 0.08 pm, less than 0.06 pm, less than 0.04 pm, less than 0.02 pm, or less than 0.01 pm.
• the second average surface roughness Ra is greater than or equal to 0.4 pm. In other examples, the second average surface roughness Ra is greater than or equal to 0.6 pm, greater than or equal to 0.8 pm, greater than or equal to 1.0 pm, greater than or equal to 1.5 pm, greater than or equal to 2 pm, greater than or equal to 2.5 pm, greater than or equal to 3 pm, greater than or equal to 3.5 pm, greater than or equal to 4 pm, greater than or equal to 4.5 pm, greater than or equal to 5 pm, greater than or equal to 5.5 pm, greater than or equal to 6 pm, greater than or equal to 6.5 mih, greater than or equal to 7 qm, greater than or equal to 7.5 qm, greater than or equal to 8 qm, greater than or equal to 8.5 qm, greater than or equal to 9 qm, greater than or equal to 9.5 qm, greater than or equal to 10 qm, or greater than or equal to 15 qm.
• methods of making aluminum can bodies comprise the steps of contacting an aluminum alloy product having two different surface roughnesses with a cupping press to form a cup comprising a cup inner surface having a cup inner surface average surface roughness and a cup outer surface having a cup outer surface average surface roughness, wherein the inner surface average surface roughness is greater than the outer surface average surface roughness; contacting the cup inner surface with a punch sleeve and contacting the cup outer surface with an ironing die; and ironing the cup to a desired height.
• the methods further comprise the step of trimming the walls to form the can body.
• any of the aluminum alloy products (such as a shate, a sheet, or a foil) described above may be used, as long as the aluminum alloy product has a difference in roughness of two of its sides.
• the outer surface average surface roughness Ra of the cup is less than 0.4 qm.
• the outer surface average surface roughness Ra is less than 0.38 qm, less than 0.36 qm, less than 0.34 qm, less than 0.32 qm, less than 0.3 qm, less than 0.28 qm, less than 0.26 qm, less than 0.24 qm, less than 0.22 qm, less than 0.2 qm, less than 0.18 qm, less than 0.16 qm, less than 0.14 qm, less than 0.12 qm, less than 0.1 qm, less than 0.08 qm, less than 0.06 qm, less than 0.04 qm, less than 0.02 qm, or less than 0.01 qm.
• the inner surface average surface roughness of the cup Ra is greater than or equal to 0.4 qm. In other examples, the inner surface average surface Ra is greater than or equal to 0.45 qm, greater than or equal to 0.5 qm, greater than or equal to 0.6 qm, greater than or equal to 0.8 qm, greater than or equal to 1.0 mih, greater than or equal to 1.5 mhi, greater than or equal to 2 mhi, greater than or equal to 2.5 gm, greater than or equal to 3 gm, greater than or equal to 3.5 gm, greater than or equal to 4 gm, greater than or equal to 4.5 gm, greater than or equal to 5 gm, greater than or equal to 5.5 gm, greater than or equal to 6 gm, greater than or equal to 6.5 gm, greater than or equal to 7 gm, greater than or equal to 7.5 gm, greater than or equal to 8 gm, greater than or equal to 8.5 gm, greater than or equal to
• Can bodies manufactured using the products and methods described herein differ from a conventional can body in that at least a portion of the can body inner surface has an average surface roughness that is greater than the average surface roughness of the can body outer surface.
• the can body comprises an inner surface having a can body inner surface average surface roughness and an outer surface having a can body outer surface average surface roughness, where the can body inner surface average surface roughness is at least 20 % greater than the can body outer surface average surface roughness.
• the can body inner surface average surface roughness is at least 22 % greater, at least 24 % greater, at least 25 % greater, at least 26 % greater, at least 28 % greater, at least 30 % greater, at least 35 % greater, at least 40 % greater, at least 45 % greater, at least 50 % greater, at least 55 % greater, at least 60 % greater, at least 65 % greater, at least 70 % greater, at least 75 % greater, at least 80 % greater, at least 85 % greater, at least 90 % greater, or at least 95 % greater than the can body outer surface average surface roughness.
• the aluminum alloy products and methods described herein can be used for preparing beverage cans, food containers, or any other desired application.
• the aluminum alloy products and methods can be used to prepare beverage can bodies.
• Aluminum alloys for use in the products and methods described herein include 3 xxx series aluminum alloys. Suitable 3xxx series aluminum alloys include, for example, AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, A A3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, A A3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.
• the aluminum alloy is AA3104.
• alloys for use in the products and methods described herein can have the following elemental composition as provided in Table 1.
• the alloy can have the following elemental composition as provided in Table 2.
• the aluminum alloy comprises 0.05 - 0.4 wt. % Cu, up to about 0.9 wt. % Fe, about 0.8 - 3.0 wt. % Mg, about 0.8 - 2.0 wt. % Mn, up to about 0.7 wt. % Si, up to about 0.1 wt. % Ti, up to about 0.25 wt. % Zn, up to about 0.15 wt. % impurities, and Al.
• the aluminum alloy comprises 0.05 - 0.25 wt. % Cu, up to about 0.8 wt. % Fe, about 0.8 - 2.8 wt. % Mg, about 0.8 - 1.4 wt. % Mn, up to about 0.6 wt. % Si, up to about 0.1 wt. % Ti, up to about 0.25 wt. % Zn, up to about 0.15 wt. % impurities, and Al.
• the aluminum alloy comprises 0.05 - 0.3 wt. % Cu, about
• the alloys described herein include copper (Cu) in an amount of from about 0.05 % to about 0.40 % (e.g., from about 0.05 % to about 0.35 % or from about 0.10 % to about 0.30 %) based on the total weight of the alloy.
• the alloy can include 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.40 % Cu. All are expressed in wt. %.
• the alloys described herein include iron (Fe) in an amount of up to about 0.9 % (e.g., from about 0.3 % to about 0.85 % or from about 0.4 % to about 0.8 %) based on the total weight of the alloy.
• the alloy can include 0 %, 0.05 %, 0.10 %, 0.15 %, 0.20%, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %,
• Fe is not present in the alloy (i.e., 0 %).A11 are expressed in wt. %.
• the alloys described herein include magnesium (Mg) in an amount of from about 0.8 % to about 3.0 % (e.g., from about 0.8 % to about 2.8 % or from about 1.0 % to about 2.5 %) based on the total weight of the alloy.
• the alloy can include 0.8 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.9 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %,
• the alloys described herein include manganese (Mn) in an amount of from about 0.1 % to about 2.0 % (e.g., from about 0.1 % to about 1.5 % or from about 0.5 % to about 1.5 %) based on the total weight of the alloy.
• the alloy can include 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.2 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %,
• the alloys described herein include silicon (Si) in an amount of up to about 0.7 % (e.g., from about 0.25 % to about 0.6 % or from about 0.3 % to about 0.55 %) based on the total weight of the alloy.
• the alloy can include 0 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1%, 0.2 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %,
• Si is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
• the alloys described herein include titanium (Ti) in an amount up to about 0.1 % (e.g., from about 0.01 % to about 0.08 % or from about 0.02 % to about 0.05 %) based on the total weight of the alloy.
• the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, or 0.1 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
• the alloys described herein include zinc (Zn) in an amount up to about 0.25 % (e.g., from about 0.01 % to about 0.25 % or from about 0.1 % to about 0.2 %) based on the total weight of the alloy.
• the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %,
• Zn is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
• the alloys described herein include chromium (Cr) in an amount up to about 0.4 % (e.g., from about 0.01 % to about 0.35 % or from about 0.05 % to about 0.3 %) based on the total weight of the alloy.
• Cr chromium
• the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.2 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.4 % Cr. In some cases, Cr is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
• the alloy compositions described herein can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below.
• impurities may include, but are not limited to Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Accordingly, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be present in alloys in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below or 0.01 % or below. In some cases, the sum of all impurities does not exceed 0.15 % (e.g., 0.10 %). All are expressed in wt. %. The remaining percentage of the alloy is aluminum.
• an aluminum alloy product for use, for example, as can end stock.
• the can end stock described herein has surfaces that are substantially isotropic, and exhibits improved formability over the standard can end stock having an anisotropic “directional” surface, referred to herein as the standard directional material.
• the increased formability of the can end stock described herein is due, at least in part, to its increased surface isotropy as compared to the standard directional material.
• “Substantially” isotropic for purposes of this application, means having at least 70 %, at least 75 %, at least 80 %, at least 85 %, or at least 95 % isotropy.
• the aluminum alloy products described herein are less prone to issues resulting from low formability, such as product cracking, particularly during a punching operation on a shell press. Not to be bound by theory, this is due, in part, to the fact that in the standard directional material, the friction in the direction 90° to the rolling direction is highest. In the standard directional material, the forming loads are increased due to direct impingement from the topographical peaks created with a standard roll ground surface. In the products described herein, however, the number of peaks is lowered by at least 10 % as compared to the standard directional material.
• the number of peaks can be lowered by at least 20 %, at least 30 %, at least 40 %, at least 50 %, at least 60 %, at least 70 %, at least 80 %, at least 90 % as compared to the standard directional material. In some cases, no peaks are present.
• the friction is balanced in all directions and the extreme loads from friction at the 90° component are lowered.
• a circular product such as a can end
• the resulting shape is not a perfect circle, but is “off-drawn” into a subtle elliptical shape with the largest diameter being in the 90° direction. This is a direct result of the higher friction (and hence higher forming load) in the 90° direction.
• the operating window for forming can be widened with the surfaces described herein to manage the “off-drawn” phenomena.
• the surface isotropy of the aluminum alloy product may be increased by any known method, such as nanosecond laser micro texturing, electrodischarge texturing, or rolling with a modified a work roll or rolling in the cross direction. It is not necessary to change the metallurgical properties (including directionality or anisotropy) of the center portion of the aluminum alloy product that result from the rolled production process; rather, benefits are present when the outer surface isotropy is increased.
• the aluminum alloy product comprises a thickness having a top portion, a center portion, and a bottom portion.
• the top and bottom portions comprise 0.1 % of the thickness of the aluminum alloy product.
• an aluminum alloy product may have a thickness of 200 pm; when the top and bottom portions comprise 1 % of the thickness, they together measure 2 pm, leaving the measurement of the center portion at 198 pm.
• the top and bottom portions comprise 0.5 % of the thickness, 1 % of the thickness, 5 % of the thickness, 10 % of the thickness, 15 % of the thickness, 20 % of the thickness, or 25 % of the thickness.
• the top and bottom portions are of equal measurement; in other cases, the top and bottom portions are not of equal measurement.
• a cross-section of an aluminum alloy product 20 comprises a top portion 21, a center portion 22, and a bottom portion 23.
• the aluminum alloy product has a surface percent isotropy of greater than 80 % as measured by confocal microscopy, and has a formability distortion of less than 10 %.
• “Surface percent isotropy” for the purposes of this application refers to isotropy as measured on a surface (top and/or bottom) of the aluminum alloy product, even if the isotropy of the aluminum alloy product varies through the thickness of the aluminum alloy product.
• the aluminum alloy product comprises a surface percent isotropy of greater than 85 %, greater than 90 %, greater than 95 %, greater than 97 %, greater than 98 %, greater than 99 %, or 100 %.
• the formability distortion is less than 9 %, less than 8 %, less than 7 %, less than 6 %, less than 5 %, less than 4 %, less than 3 %, less than 2 %, less than 1 %, or zero.
• a stamped can end
• the aluminum alloy products useful for can end stock described herein can have any suitable gauge.
• the aluminum alloy product can be a sheet.
• the sheet can be used as can end stock.
• the aluminum alloy product is a sheet such as a can end sheet. In some examples, the aluminum alloy is a 5xxx series aluminum alloy.
• Suitable 5xxx series aluminum alloys include, for example, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA
• the anisotropy of the surface can be measured by the Texture Aspect Ratio (Str), according to ISO 25178, as described above.
• the Str value is the ratio of the shortest wavelength to the longest wavelength measured in any direction relative to the rolling direction.
• the Str value for the surface of alloy sheet as described herein is greater than about 0.7.
• the Str value can be 0.71, 0.75, 0.8, 0.85, 0.9, 0.95, 0.96, 0.97, 0.98, 0.99 or 1.0.
• Conventional aluminum alloy sheets used to prepare can end stock, however, typically have an anisotropic surface texture.
• the Str value for the surface of a conventional alloy sheet is less than 0.1.
• the anisotropic nature of conventional can end stock can cause formability issues, such as split domes and tear offs.
• the aluminum alloy products useful for can end stock described herein are free of significant anisotropy.
• Illustration 1 is an aluminum alloy product, comprising a first surface having a first average surface roughness; and a second surface having a second average surface roughness, wherein the first average surface roughness is at least 20 % lower than the second average surface roughness, as measured by a surface profilometer.
• Illustration 2 is the aluminum alloy of any preceding or subsequent illustration, wherein the first average surface roughness is at least 30 % lower than the second average surface roughness.
• Illustration 3 is the aluminum alloy of any preceding or subsequent illustration, wherein the first average surface roughness is less than 0.4 pm.
• Illustration 4 is the aluminum alloy of any preceding or subsequent illustration, wherein the second average surface roughness is greater than or equal to 0.4 pm.
• Illustration 5 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product comprises a 3xxx series aluminum alloy.
• Illustration 6 is the aluminum alloy of any preceding or subsequent illustration, wherein the 3xxx series aluminum alloy comprises an AA3104 aluminum alloy.
• Illustration 7 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product comprises about 0.05 - 0.25 wt. % Cu, up to about 0.8 wt. % Fe, about 0.8 - 1.3 wt. % Mg, about 0.8 - 1.4 wt. % Mn, up to about 0.6 wt. % Si, up to about 0.1 wt. % Ti, up to about 0.25 wt. % Zn, , up to about 0.05 wt. % impurities, and Al..
• Illustration 8 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product comprises a thickness of less than about 4 mm.
• Illustration 9 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product is an aluminum can body.
• Illustration 10 is a method of making an aluminum can body, comprising contacting the aluminum alloy product of claim 1 with a cupping press to form a cup comprising a cup inner surface corresponding to the second surface and having a cup inner surface average surface roughness and a cup outer surface corresponding to the first surface and having a cup outer surface average surface roughness, wherein the cup inner surface average surface roughness is greater than the cup outer surface average surface roughness; contacting the cup inner surface with a punch sleeve and contacting the cup outer surface with an ironing die; and ironing the cup to a desired height.
• Illustration 11 is the method of any preceding or subsequent illustration, wherein the cup has walls and the method further comprises trimming the walls to form the can body, wherein the can body has a can body inner surface and a can body outer surface.
• Illustration 12 is the method of any preceding or subsequent illustration, wherein the cup outer surface average surface roughness is less than 0.4 pm.
• Illustration 13 is the method of any preceding or subsequent illustration, wherein the cup inner surface average surface roughness is greater than or equal to 0.4 pm.
• Illustration 14 is the method of any preceding or subsequent illustration, wherein the aluminum can body comprises an inner surface having a can body inner surface average surface roughness and an outer surface having a can body outer surface average surface roughness, wherein can body inner surface average surface roughness is at least 2 0% greater than the can body outer surface average surface roughness.
• Illustration 15 is an aluminum alloy product comprising a surface percent isotropy of greater than 80 % as measured by confocal microscopy, and comprising a formability distortion of less than 10 %.
• Illustration 16 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product comprises an isotropy of greater than 95 %.
• Illustration 17 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product comprises a 5xxx series aluminum alloy.
• Illustration 18 is the aluminum alloy of any preceding or subsequent illustration, wherein the 5xxx series aluminum alloy comprises a 5182 aluminum alloy.
• Illustration 19 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product is an aluminum can end.
• Illustration 20 is the aluminum alloy of any preceding or subsequent illustration, wherein the aluminum alloy product comprises a Texture Aspect Ratio (Str) value of greater than 0.7, according to ISO 25178.

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