WO2022165044A2 - New 6xxx aluminum alloys - Google Patents
New 6xxx aluminum alloys Download PDFInfo
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- WO2022165044A2 WO2022165044A2 PCT/US2022/014108 US2022014108W WO2022165044A2 WO 2022165044 A2 WO2022165044 A2 WO 2022165044A2 US 2022014108 W US2022014108 W US 2022014108W WO 2022165044 A2 WO2022165044 A2 WO 2022165044A2
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- WO
- WIPO (PCT)
- Prior art keywords
- aluminum alloy
- sheet product
- alloy sheet
- mpa
- temper
- Prior art date
Links
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 305
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 43
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 42
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 29
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 23
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 22
- 229910052742 iron Inorganic materials 0.000 claims abstract description 21
- 229910052720 vanadium Inorganic materials 0.000 claims abstract description 21
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 21
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 20
- 229910052802 copper Inorganic materials 0.000 claims abstract description 19
- 239000012535 impurity Substances 0.000 claims abstract description 16
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 8
- 230000032683 aging Effects 0.000 claims description 50
- 239000000047 product Substances 0.000 description 91
- 239000000956 alloy Substances 0.000 description 74
- 229910045601 alloy Inorganic materials 0.000 description 73
- 238000012360 testing method Methods 0.000 description 44
- 239000011572 manganese Substances 0.000 description 37
- 239000011651 chromium Substances 0.000 description 35
- 239000000463 material Substances 0.000 description 23
- 239000010936 titanium Substances 0.000 description 22
- 239000011777 magnesium Substances 0.000 description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 18
- 238000000034 method Methods 0.000 description 16
- 239000002245 particle Substances 0.000 description 14
- 239000010949 copper Substances 0.000 description 12
- 239000000470 constituent Substances 0.000 description 11
- 239000011701 zinc Substances 0.000 description 11
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 8
- 238000013001 point bending Methods 0.000 description 8
- 238000005260 corrosion Methods 0.000 description 7
- 230000007797 corrosion Effects 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000003973 paint Substances 0.000 description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 6
- 239000011575 calcium Substances 0.000 description 6
- 238000001887 electron backscatter diffraction Methods 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 238000001953 recrystallisation Methods 0.000 description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 5
- 238000005266 casting Methods 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- 239000011164 primary particle Substances 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- 238000013459 approach Methods 0.000 description 4
- 238000005097 cold rolling Methods 0.000 description 4
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000004364 calculation method Methods 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 238000005242 forging Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000011002 quantification Methods 0.000 description 3
- 238000010791 quenching Methods 0.000 description 3
- 230000004044 response Effects 0.000 description 3
- 238000005464 sample preparation method Methods 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 238000005482 strain hardening Methods 0.000 description 3
- 229910001369 Brass Inorganic materials 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 229910052790 beryllium Inorganic materials 0.000 description 2
- 239000010951 brass Substances 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000010191 image analysis Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 230000000171 quenching effect Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 229910052712 strontium Inorganic materials 0.000 description 2
- 238000007669 thermal treatment Methods 0.000 description 2
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- RILZRCJGXSFXNE-UHFFFAOYSA-N 2-[4-(trifluoromethoxy)phenyl]ethanol Chemical compound OCCC1=CC=C(OC(F)(F)F)C=C1 RILZRCJGXSFXNE-UHFFFAOYSA-N 0.000 description 1
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 101150051106 SWEET11 gene Proteins 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 229940117975 chromium trioxide Drugs 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N chromium trioxide Inorganic materials O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- GAMDZJFZMJECOS-UHFFFAOYSA-N chromium(6+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Cr+6] GAMDZJFZMJECOS-UHFFFAOYSA-N 0.000 description 1
- 239000008119 colloidal silica Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000002178 crystalline material Substances 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 230000010339 dilation Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 235000012438 extruded product Nutrition 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000005098 hot rolling Methods 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- YTHCQFKNFVSQBC-UHFFFAOYSA-N magnesium silicide Chemical compound [Mg]=[Si]=[Mg] YTHCQFKNFVSQBC-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000001000 micrograph Methods 0.000 description 1
- 238000000386 microscopy Methods 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 238000011020 pilot scale process Methods 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000003303 reheating Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000001878 scanning electron micrograph Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 238000010200 validation analysis Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- 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
- C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
Definitions
- [001 ] 6xxx aluminum alloys are aluminum alloys having silicon and magnesium to produce the precipitate magnesium silicide (Mg2Si).
- the alloy 6061 has been used in various applications for several decades. However, improving one or more properties of an aluminum alloy without degrading other properties is elusive. For automotive applications, a sheet having good formability prior to thermal treatment but with high strength after thermal treatment would be useful.
- the present patent application relates to new 6xxx aluminum alloys and methods for making the same.
- the new 6xxx aluminum alloys generally include from 0.75 to 1.05 wt. % Si, from 0.65 to 0.95 wt. % Mg, wherein the weight ratio of Mg:Si [i.e., (wt. % Mg) / (wt. % Si)] is not greater than 0.99: 1, from 0.50 to 0.75 wt. % Cu, from 0.02 to 0.40 wt. % Mn, from 0.06 to 0.26 wt. % Cr, wherein (wt. % Mn) + (wt. % Cr) is at least 0.22 wt.
- the new 6xxx aluminum alloy is in the form of a rolled 6xxx aluminum alloy sheet product having a thickness of from 0.5 to 4.0 mm. Products made from the new 6xxx aluminum alloys may realize an improved combination of properties, such as an improved combination of two or more of strength, ductility (elongation), fracture behavior and corrosion resistance.
- the new aluminum alloys may be used in a variety of applications, such as in automotive applications (e.g., as a sheet product).
- the 6xxx new aluminum alloys generally comprises (and in some instances consist essentially of, or consist of) from 0.75 to 1.05 wt. % Si, from 0.65 to 0.95 wt. % Mg, wherein (wt. % Mg) / (wt. % Si) is not greater than 0.99: 1, from 0.50 to 0.75 wt. % Cu, from 0.02 to 0.40 wt. % Mn, from 0.06 to 0.26 wt. % Cr, wherein (wt. % Mn) + (wt. % Cr) is at least 0.22 wt. %, from 0.01 to 0.30 wt. % Fe, up to 0.25 wt.
- the new 6xxx aluminum alloys generally include from 0.75 to 1.05 wt. % Si. Silicon may facilitate strength.
- a new aluminum alloy includes at least 0.80 wt. % Si.
- a new aluminum alloy includes at least 0.85 wt. % Si.
- a new aluminum alloy includes at least 0.90 wt. % Si.
- a new aluminum alloy includes not greater than 1.0 wt. % Si.
- the new aluminum alloys generally include from 0.65 to 0.95 wt. % Mg. Magnesium may facilitate strength. In one embodiment, a new aluminum alloy includes at least 0.70 wt. % Mg. In another embodiment, a new aluminum alloy includes at least 0.75 wt. % Mg. In another embodiment, a new aluminum alloy includes at least 0.80 wt. % Mg. In one embodiment, a new aluminum alloy includes not greater than 0.90 wt. % Mg.
- the weight ratio of Mg: Si is generally not greater than 0.99: 1.
- the appropriate Mg: Si ratio may facilitate high strength and good ductility.
- a weight ratio of Mg: Si is not greater than 0.95 : 1.
- a weight ratio of Mg: Si is not greater than 0.9:1.
- a weight ratio of Mg: Si is at least 0.7: 1.
- a weight ratio of Mg:Si is at least 0.8: 1.
- the new aluminum alloys generally include from 0.50 to 0.75 wt. % Cu. Copper may facilitate, for instance, strength, natural aging response and/or formability.
- a new aluminum alloy includes at least 0.55 wt. % Cu.
- a new aluminum alloy includes at least 0.60 wt. % Cu.
- a new aluminum alloy includes at least 0.65 wt. % Cu.
- a new aluminum alloy includes not greater than 0.73 wt. % Cu.
- a new aluminum alloy includes not greater than 0.70 wt. % Cu.
- the new aluminum alloys generally include from 0.02 to 0.40 wt. % Mn.
- Manganese may facilitate precipitation of dispersoids that at least partially assist in providing the proper grain structure.
- the amount of manganese in the alloy should be restricted such that large primary particles are avoided / restricted / limited during production of aluminum alloy products.
- a new aluminum alloy includes at least 0.04 wt. % Mn.
- a new aluminum alloy includes at least 0.05 wt. % Mn.
- a new aluminum alloy includes at least 0.06 wt. % Mn.
- a new aluminum alloy includes at least 0.08 wt. % Mn.
- a new aluminum alloy includes at least 0.10 wt. % Mn. In yet another embodiment, a new aluminum alloy includes at least 0.15 wt. % Mn. In another embodiment, a new aluminum alloy includes at least 0.20 wt. % Mn. In one embodiment, a new aluminum alloy includes not greater than 0.35 wt. % Mn. In another embodiment, a new aluminum alloy includes not greater than 0.30 wt. % Mn. [009] As noted above, the new aluminum alloys generally include from 0.06 to 0.26 wt. % Cr. Chromium in combination with manganese may facilitate a unique distribution of dispersoid particles, which may facilitate achievement of high strength in combination with high three- point bending (fracture) properties.
- a new aluminum alloy includes at least 0.08 wt. % Cr. In another embodiment, a new aluminum alloy includes at least 0.10 wt. % Cr. In yet another embodiment, a new aluminum alloy includes at least 0.12 wt. % Cr. In another embodiment, a new aluminum alloy includes at least 0.14 wt. % Cr. In yet another embodiment, a new aluminum alloy includes at least 0.16 wt. % Cr. In another embodiment, a new aluminum alloy includes at least 0.18 wt. % Cr. In one embodiment, a new aluminum alloy includes not greater than 0.24 wt. % Cr. In another embodiment, a new aluminum alloy includes not greater than 0.22 wt. % Cr. In yet another embodiment, a new aluminum alloy includes not greater than 0.20 wt. % Cr.
- the new aluminum alloys generally include at least 0.22 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.22 wt. %, as noted above.
- a new aluminum alloy includes at least 0.24 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.24 wt. %.
- a new aluminum alloy includes at least 0.25 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.25 wt. %.
- a new aluminum alloy includes at least 0.26 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.26 wt. %.
- a new aluminum alloy includes at least 0.27 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.27 wt. %.
- a new aluminum alloy includes at least 0.28 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.28 wt. %.
- a new aluminum alloy includes at least 0.29 wt. % (Mn+Cr), i.e., (wt. % Mn) + (wt. % Cr) is at least 0.29 wt. %.
- the new aluminum alloys generally include from 0.01 to 0.30 wt. % Fe. Iron may facilitate a proper grain structure and using more than 0.10 wt. % Fe iron may be cost effective. The amount of iron in the alloy should be restricted such that large primary particles are avoided / restricted / limited during production of aluminum alloy products.
- a new aluminum alloy includes at least 0.05 wt. % Fe.
- a new aluminum alloy includes at least 0.10 wt. % Fe.
- a new aluminum alloy includes at least 0.12 wt. % Fe.
- a new aluminum alloy includes not greater than 0.28 wt. % Fe.
- a new aluminum alloy includes not greater than 0.26 wt. % Fe.
- the new aluminum alloys may include up to 0.25 wt. % Zn.
- a new aluminum alloy includes not greater than 0.20 wt. % Zn.
- a new aluminum alloy includes not greater than 0.15 wt. % Zn.
- a new aluminum alloy includes not greater than 0.10 wt. % Zn.
- a new aluminum alloy includes not greater than 0.08 wt. % Zn.
- a new aluminum alloy includes not greater than 0.05 wt. % Zn.
- a new aluminum alloy includes not greater than 0.03 wt. % Zn.
- a new aluminum alloy includes at least 0.01 wt. % Zn.
- the new aluminum alloys include not greater than 0.20 wt. % Zr. Zirconium is less preferred than manganese and chromium, but still may be useful. The amount of zirconium in the alloy should be restricted such that large primary particles are avoided / restricted / limited during production of aluminum alloy products.
- a new aluminum alloy includes not greater than 0.15 wt. % Zr. In another embodiment, a new aluminum alloy includes not greater than 0.10 wt. % Zr. In yet another embodiment, a new aluminum alloy includes not greater than 0.08 wt. % Zr. In another embodiment, a new aluminum alloy includes not greater than 0.03 wt. % Zr.
- a new aluminum alloy includes not greater than 0.01 wt. % Zr. In one embodiment, a new aluminum alloy includes at least 0.01 wt. % Zr (e.g., when Zr is added/used to the alloy for grain structure control.) In another embodiment, a new aluminum alloy includes at least 0.05 wt. % Zr. In one embodiment, a new aluminum alloy includes from 0.07 to 0.15 wt. % Zr.
- the new aluminum alloys include not greater than 0.20 wt. % V. Vanadium is less preferred than manganese and chromium, but still may be useful. The amount of vanadium in the alloy should be restricted such that large primary particles are avoided / restricted / limited during production of aluminum alloy products.
- a new aluminum alloy includes not greater than 0.15 wt. % V.
- a new aluminum alloy includes not greater than 0.10 wt. % V.
- a new aluminum alloy includes not greater than 0.08 wt. % V.
- a new aluminum alloy includes not greater than 0.03 wt. % V.
- a new aluminum alloy includes not greater than 0.01 wt. % V. In one embodiment, a new aluminum alloy includes at least 0.01 wt. % V (e.g., when V is added/used to the alloy for grain structure control.) In another embodiment, a new aluminum alloy includes at least 0.05 wt. % V. In one embodiment, a new aluminum alloy includes from 0.07 to 0.15 wt. % V.
- the new aluminum alloys include not greater than 0.25 wt. % Ti. Titanium may be used during casting for grain refinement. Higher levels of titanium may also facilitate corrosion resistance. The amount of titanium in the alloy should be restricted such that large primary particles are avoided / restricted / limited during production of alloy products.
- a new aluminum alloy includes at least 0.005 wt. % Ti.
- a new aluminum alloy includes at least 0.01 wt. %Ti.
- a new aluminum alloy includes at least 0.02 wt. %Ti.
- a new aluminum alloy includes at least 0.05 wt. % Ti.
- a new a new aluminum alloy includes not greater than 0.20 wt. %Ti. In another embodiment, a new a new aluminum alloy includes not greater than 0.15 wt. %Ti. In another embodiment, a new aluminum alloy includes not greater than 0.12 wt. % Ti. In yet another embodiment, a new a new aluminum alloy includes not greater than 0.10 wt. %Ti. In another embodiment, a new a new aluminum alloy includes not greater than 0.08 wt. %Ti. In yet another embodiment, a new a new aluminum alloy includes not greater than 0.05 wt. %Ti. In another embodiment, a new a new aluminum alloy includes not greater than 0.03 wt. %Ti.
- a new a new aluminum alloy includes from 0.005 to 0.10 wt. % Ti. In another embodiment, a new aluminum alloy includes from 0.01 to 0.05 wt. % Ti. In yet another embodiment, a new aluminum alloy includes from 0.01 to 0.03 wt. % Ti.
- the titanium may be in elemental form or in the form of compounds (e.g., TiB 2 or TiC).
- incidental elements means those elements or materials, other than the above listed elements, that may optionally be added to the alloy to assist in the production of the alloy.
- incidental elements include casting aids, such as grain refiners and deoxidizers.
- Optional incidental elements may be included in the alloy in a cumulative amount of up to 1.0 wt. %.
- one or more incidental elements may be added to the alloy during casting to reduce or restrict (and is some instances eliminate) ingot cracking due to, for example, oxide fold, pit and oxide patches. These types of incidental elements are generally referred to herein as deoxidizers.
- Examples of some deoxidizers include Ca, Sr, and Be.
- calcium (Ca) is included in the alloy, it is generally present in an amount of up to about 0.05 wt. %, or up to about 0.03 wt. %.
- Ca is included in the alloy in an amount of about 0.001-0.03 wt. %, such as 0.001-0.008 wt. % (or 10 to 80 ppm).
- Strontium (Sr) may be included in the alloy as a substitute for Ca (in whole or in part), and thus may be included in the alloy in the same or similar amounts as Ca.
- Be beryllium
- some embodiments of the alloy are substantially Be-free.
- Be is included in the alloy, it is generally present in an amount of up to about 20 ppm.
- Incidental elements may be present in minor amounts, or may be present in significant amounts, and may add desirable or other characteristics on their own without departing from the alloy described herein, so long as the alloy retains the desirable characteristics described herein. It is to be understood, however, that the scope of this disclosure should not/cannot be avoided through the mere addition of an element or elements in quantities that would not otherwise impact on the combinations of properties desired and attained herein.
- the new aluminum alloys may contain low amounts of impurities.
- a new aluminum alloy includes not greater than 0.15 wt. %, in total, of the impurities, and wherein the new aluminum alloy includes not greater than 0.05 wt. % of each of the impurities.
- a new aluminum alloy includes not greater than 0.10 wt. %, in total, of the impurities, and wherein the new aluminum alloy includes not greater than 0.03 wt. % of each of the impurities.
- the new aluminum alloys may be useful in a variety of product forms, including ingot or billet, wrought product forms (sheet, plate, forgings and extrusions), shape castings, additively manufactured products, and powder metallurgy products, for instance.
- the new aluminum alloys may be processed into a variety of wrought forms, such as in rolled form (sheet, plate), as an extrusion, or as a forging, and in a variety of tempers.
- the new aluminum alloys may be cast (e.g., direct chill cast or continuously cast), and then worked (hot and/or cold worked) into the appropriate product form (sheet, plate, extrusion, or forging).
- the new aluminum alloys may be processed to one of a T temper, a W temper, O temper, or an F temper as per ANSI H35.1 (2009).
- a new aluminum alloy is processed to a “T temper” (thermally treated).
- the new aluminum alloys may be processed to any of a Tl, T2, T3, T4, T5, T6, T7, T8, T9 or T10 temper as per ANSI H35.1 (2009).
- the product is processed to a T43 temper.
- the product is processed to a T6 temper.
- a new aluminum alloy is processed to a “W temper” (solution heat treated).
- no solution heat treatment is applied after working the aluminum alloy into the appropriate product form, and thus the new aluminum alloys may be processed to an “F temper” (as fabricated) or “O temper” (annealed).
- a new aluminum alloy is in the form of a sheet product.
- the sheet product has a thickness of from 0.5 to 4.0 mm, or a thickness of from 1.0 to 4.0 mm.
- the sheet product is processed to a T4 temper.
- the sheet product is processed to a T43 temper.
- the sheet product is processed to a T4 or T43 temper and then paint baked (e.g., by heating at 180°C for 20 minutes).
- the sheet product is processed to a T4 or T43 temper, then paint baked, and then artificially aged (e.g., by heating at 180°C for 8 hours).
- the sheet product is processed to a T4 or T43 temper, then artificially aged and then paint baked.
- Such paint baked sheet products may be useful in automotive applications, as described in further detail below.
- the T43 temper refers to products that have been processed by preaging, whether by cooling from an elevated temperature to a pre-aging temperature (e.g., after quench), or by reheating to the pre-aging temperature or otherwise.
- a T43 temper product may be solution heat treated, then quenched to a suitable cooled temperature (e.g., below approximately 104.4°C (220°F)), then pre-aged at a suitable pre-aging temperature (e.g., between 50-180°C), and then slowly cooled to room temperature (e.g., coil cooled or Newtonian cooling), after which the product is allowed to naturally age for several days or weeks.
- a suitable cooled temperature e.g., below approximately 104.4°C (220°F)
- pre-aged at a suitable pre-aging temperature e.g., between 50-180°C
- room temperature e.g., coil cooled or Newtonian cooling
- the product may be cooled to room temperature or thereabouts and then reheated to a pre-
- the new aluminum alloys may realize a unique microstructure.
- a new aluminum alloy is at least 60% recrystallized, i.e., contains at least 60 vol. % recrystallized grains as determined in accordance with the Microstructure Assessment Procedure, described in the Definitions section, below.
- a new aluminum alloy sheet is at least 70% recrystallized.
- a new aluminum alloy sheet is at least 80% recrystallized.
- a new aluminum alloy sheet is at least 90% recrystallized.
- an aluminum alloy sheet product is “fully recrystallized” when it is determined to have at least 90 vol. % recrystallized grains.
- a new aluminum alloy realizes an area weighted average grain size of not greater than 50 micrometers as determined in accordance with the Microstructure Assessment Procedure, described in the Definitions section, below.
- a new aluminum alloy realizes an area weighted average grain size of not greater than 45 micrometers.
- a new aluminum alloy realizes an area weighted average grain size of not greater than 40 micrometers.
- a new aluminum alloy realizes an area weighted average grain size of not greater than 38 micrometers.
- a new aluminum alloy realizes an area weighted average grain size of not greater than 36 micrometers.
- a new aluminum alloy realizes an area weighted average grain size of not greater than 34 micrometers. In yet another embodiment, a new aluminum alloy realizes an area weighted average grain size of not greater than 32 micrometers. In another embodiment, a new aluminum alloy realizes an area weighted average grain size of not greater than 30 micrometers. In one embodiment, a new aluminum alloy realizes an area weighted average grain size of at least 20 micrometers. In another embodiment, a new aluminum alloy realizes an area weighted average grain size of at least 25 micrometers. In yet another embodiment, a new aluminum alloy realizes an area weighted average grain size of at least 28 micrometers.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.5% as determined in accordance with the Microstructure Assessment Procedure, described in the Definitions section, below.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.55%.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.6%.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.65%.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.7%.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.75%.
- a new aluminum alloy realizes a dispersoid area fraction of at least 0.8%. In another embodiment, a new aluminum alloy realizes a dispersoid area fraction of at least 0.85%. In yet another embodiment, a new aluminum alloy realizes a dispersoid area fraction of at least 0.9%. In another embodiment, a new aluminum alloy realizes a dispersoid area fraction of not greater than 1.1%. In yet another embodiment, a new aluminum alloy realizes a dispersoid area fraction of not greater than 1.0%.
- a new aluminum alloy realizes an f/r value at least 0.05 as determined in accordance with the Microstructure Assessment Procedure, described in the Definitions section, below.
- a new aluminum alloy realizes an f/r value at least 0.06.
- a new aluminum alloy realizes an f/r value at least 0.07.
- a new aluminum alloy realizes an f/r value at least 0.08.
- a new aluminum alloy realizes an f/r of not greater than 0.11.
- a new aluminum alloy realizes an f/r of not greater than 0.10.
- a new aluminum alloy contains at least 10 vol. % cube texture as determined in accordance with the Microstructure Assessment Procedure, described in the Definitions section, below. In another embodiment, a new aluminum alloy contains at least 11 vol. % cube texture. In another embodiment, a new aluminum alloy contains at least 12 vol. % cube texture. In another embodiment, a new aluminum alloy contains at least 13 vol. % cube texture. In another embodiment, a new aluminum alloy contains at least 14 vol. % cube texture. In another embodiment, a new aluminum alloy contains at least 15 vol. % cube texture. In one embodiment, a new aluminum alloy contains not greater than 25 vol. % cube texture. In one embodiment, a new aluminum alloy contains not greater than 20 vol. % cube texture. iv. Properties
- the new aluminum alloys may realize an improved combination of properties.
- products made from the new 6xxx aluminum alloys may realize an improved combination of two or more of strength, ductility (elongation), fracture behavior and corrosion resistance.
- the new aluminum alloy is a sheet product having a thickness of from 1.0 to 4.0 mm, and this aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 315 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225 °C (437°F).
- the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 320 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F).
- the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 325 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 330 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In yet another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 335 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F).
- the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 340 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In yet another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 345 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 350 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F).
- the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 355 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 360 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In yet another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 365 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F). In another embodiment, the aluminum alloy sheet product realizes a tensile yield strength (LT) of at least 370 MPa in a T6 temper, wherein the artificial aging of the T6 temper is 30 minutes at 225°C (437°F).
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing high three-point bend extensions in one or both of (a) the T4 temper or (b) the T6 pre-strained temper as per the “three-point bending test” described in the Definitions section, below. As noted below, all three-point bend testing is to be conducted on a sheet having a thickness of 2.0 ⁇ 0.05 mm. Thus, for an aluminum alloy sheet product having a thickness of from 0.5 to 1.94 mm or 2.06 to 4.0 mm, the bend extension for such a product is determined by reproducing the product at 2.0 ⁇ 0.05 mm, after which its three-point bend extension is measured.
- the “T4” temper includes both the T4 temper and the T43 temper, and means the final gauge aluminum alloy sheet product is solution heat treated and quenched and then naturally aged for 1 -month; pre-aging will occur after solution heat treatment for a T43 temper product.
- the “T6 temper” means the final gauge aluminum alloy sheet product is solution heat treated and quenched, then naturally aged for at least 2 weeks, and then artificially aged at 225°C (437°F) for 30 minutes.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 16.0 mm in the T4 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 16.2 mm in the T4 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 16.4 mm in the T4 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 16.6 mm in the T4 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 16.8 mm in the T4 temper. In yet another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 17.0 mm in the T4 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 17.2 mm in the T4 temper. In yet another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 17.4 mm in the T4 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 17.6 mm in the T4 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 17.8 mm in the T4 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 18.0 mm in the T4 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 10.0 mm in the T6 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 10.5 mm in the T6 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 11.0 mm in the T6 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 11.2 mm in the T6 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 11.4 mm in the T6 temper. In yet another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 11.6 mm in the T6 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 11.8 mm in the T6 temper. In yet another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 12.0 mm in the T6 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 12.2 mm in the T6 temper.
- a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 12.4 mm in the T6 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 12.6 mm in the T6 temper. In yet another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 12.8 mm in the T6 temper. In another embodiment, a new aluminum alloy sheet product has a thickness of 1.0 to 4.0 mm and is capable of realizing a three-point bend extension of at least 13.0 mm in the T6 temper.
- a new aluminum alloy is corrosion resistant, realizing a maximum depth of attack of not greater than 200 micrometers when tested in accordance with ASTM G110-92(2015) for 6 hours.
- a new aluminum alloy is strength increase resistant in the T4 or T43 temper, realizing a tensile yield strength (LT) increase of not greater than 15 MPa as measured from the period starting after 2 weeks of natural aging (+/- 12 hours) and ending after 6 months of natural aging (+/- 24 hours) (i.e., the “Test Time Period”).
- LT tensile yield strength
- the aluminum alloy sheet in the T4 temper would have realized a tensile yield strength (LT) increase of 4 MPa (189-185 MPa) over the Test Time Period.
- the tensile yield strength (LT) increase in the T4/T43 temper is not greater than 13 MPa over the Test Time Period.
- the tensile yield strength (LT) increase in the T4/T43 temper is not greater than 11 MPa over the Test Time Period.
- the tensile yield strength (LT) increase in the T4/T43 temper is not greater than 9 MPa over the Test Time Period. In another embodiment, the tensile yield strength (LT) increase in the T4/T43 temper is not greater than 7 MPa over the Test Time Period. In yet another embodiment, the tensile yield strength (LT) increase in the T4/T43 temper is not greater than 5 MPa, or less, over the Test Time Period.
- a new aluminum alloy is strength loss resistant relative to the T6 temper, realizing a tensile yield strength (LT) loss of not greater than 21 MPa over the Test Time Period, wherein a first piece of a material is artificially aged after 2 weeks of natural aging and a second piece of that same material is artificially aged after 6 months of natural aging, wherein the same artificially aging practice is used for both the first and second pieces.
- LT tensile yield strength
- the aluminum alloy sheet in the T6 temper would have realized a tensile yield strength (LT) loss of only 10 MPa (235-245 MPa) over the Test Time Period.
- the tensile yield strength (LT) loss relative to the T6 temper is not greater than 19 MPa over the Test Time Period.
- the tensile yield strength (LT) loss relative to the T6 temper is not greater than 17 MPa over the Test Time Period. In yet another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 15 MPa over the Test Time Period. In another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 13 MPa over the Test Time Period. In yet another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 11 MPa over the Test Time Period. In another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 9 MPa over the Test Time Period.
- the tensile yield strength (LT) loss relative to the T6 temper is not greater than 7 MPa over the Test Time Period. In another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 5 MPa over the Test Time Period. In yet another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 3 MPa over the Test Time Period. In another embodiment, the tensile yield strength (LT) loss relative to the T6 temper is not greater than 1 MPa over the Test Time Period. In one embodiment, the aluminum alloy sheet product realizes no tensile yield strength (LT) loss relative to the T6 temper over the Test Time Period. In another embodiment, the aluminum alloy sheet product realizes an increase in tensile yield strength of at least 2 MPa relative to the T6 temper over the Test Time Period. v. Product Applications
- the new aluminum alloy described herein may be used in a variety of applications, such as an automotive, rail, aerospace, or consumer electronics application.
- a new aluminum alloy may be formed into an automotive part.
- automotive parts include automotive bodies and automotive panels.
- Non-limiting examples of automotive panels may be outer panels, inner panels for use in car doors, car hoods, or car trunks (deck lids), among others.
- One example of an automotive body product may be a structural component, which are commonly sheet metal components of a car body (e.g., body-in-white) where additional strength is required to withstand crash requirements.
- the new aluminum alloy is an enclosure for a battery, such as a battery used in an electric vehicle.
- the new aluminum alloys may also be used in other transportation applications, such as light or heavy trucks.
- Consumer electronic product applications include laptop computer cases, battery cases, among other stamped and formed products.
- “Wrought aluminum alloy product” means an aluminum alloy product that is hot worked after casting, and includes rolled products (sheet or plate), forged products, and extruded products.
- Hot working such as by hot rolling means working the aluminum alloy product at elevated temperature, and generally at least 121.1°C (250°F). Strain-hardening is restricted / avoided during hot working, which generally differentiates hot working from cold working.
- Cold working such as by cold rolling means working the aluminum alloy product at temperatures that are not considered hot working temperatures, generally below about 121.1 °C (250°F) (e.g., at ambient).
- Test Time Period means the period beginning after two weeks of natural aging (+/- 12 hours) and ending after six months of natural aging (+/- 24 hours).
- the Test Time Period is applicable to measurement of T4/T43 strength increase (or lack thereof) and to measurement of T6 strength loss (or lack thereof), as explained above. See also, Example 3, below.
- Temper definitions are per ANSI H35.1 (2009), entitled “American National Standard Alloy and Temper Designation Systems for Aluminum,” published by The Aluminum Association.
- “Three-point bending tests” (sometimes called 3 -point bending tests) are measured in accordance with VDA 238-100, entitled, Plate bending test for metallic materials, Validation Rule, 01 June 2017 (see https://www.vda.de/en/services/Publications/vda-238- 100-plate- bending-test-for-metallic-materials.html), where the final gauge (thickness) of the sheet is 2.0 ⁇ 0.05 mm, the coupon is fixed in the test frame, and a punch radius of 0.2 mm is used, except the VDA test is modified as follows:
- the specimen size is 25 mm wide and 51 mm long; the extension at 70% load drop is used as a metric, with higher extensions representing greater fracture toughness or crash resistance (the normal test VDA 238-100 utilizes the bend angle measured after 5% drop in load as a metric for comparing materials).
- microstructure features e.g., percent recrystallization, dispersoid content and size, constituent content and size, texture
- Dispersoid area fraction is the area fraction covered by dispersoid particles divided by the total area examined in a two-dimensional cross section prepared by standard metallographic sample preparation methods.
- Disposoid area % is determined via the formula f x 100.
- backscattered electron images should be taken at 2000x on an Apreo S Field Emission Gun (Thermo Fisher Scientific, Waltham, MA, U.S.A) scanning electron microscope, or equivalent, to image dispersoids.
- the images should be taken using an accelerating voltage 5kV. Beam current should be 3.2 nanoamps.
- Twenty images are to be collected from metallographically polished specimens for each alloy at both t/2 and the surface. Image analysis is to be used to quantify the images.
- the pixel size for quantifying dispersoids is 0.021 microns, and only particles containing at least 15 pixels but no more than 300 pixels are to be counted. Pixels are only counted if their gray scale value is 4 standard deviations above the mean pixel gray scale value across entire image. For each dispersoid particle, the number of pixels is converted to a particle area and to a particle effective diameter.
- the quantity “f/r” is the dispersoid area fraction, f, divided by the dispersoid radius, which is determined by taking half of the dispersoid average diameter. This parameter is a measure of the pinning force on grain boundaries, also called Zener drag, (Ref. l), where higher values may be associated with finer grain size.
- Constant area fraction is the area fraction covered by constituent particles divided by the total area examined in a two-dimensional cross section prepared by standard metallographic sample preparation methods.
- Constant area % is determined via the formula cf x (times) 100.
- Constant average diameter is the average of all measured constituent diameters, di, where each diameter is an effective diameter calculated assuming each constituent area, Ai, measured on a two-dimensional cross section is a circle of the effective diameter:
- backscattered electron images should be taken at 500x on an Apreo S Field Emission Gun (Thermo Fisher Scientific, Waltham, MA, U.S.A) scanning electron microscope, or equivalent, to image dispersoids.
- the images should be taken using an accelerating voltage 5kV. Beam current should be 3.2 nanoamps.
- Twenty images are to be collected from metallographically polished specimens for each alloy at both t/2 and the surface. Image analysis is to be used to quantify the images.
- the pixel size for quantifying dispersoids is 0.083 microns, and only particles containing at least 23 pixels are to be counted. Pixels are only counted if their gray scale value is 4 standard deviations above the mean pixel gray scale value across entire image. For each dispersoid particle, the number of pixels is converted to a particle area and to a particle effective diameter.
- Percent recrystallized and the like means the volume percent of a wrought aluminum alloy product having recrystallized grains.
- the amount of recrystallized grains is determined by EBSD (electron backscatter diffraction) analysis of a suitable number of SEM micrographs of the wrought aluminum alloy product, as per the Recrystallization Determination Procedure, below. Generally at least 5 micrographs should be analyzed.
- “Recrystallized grains” means those grains of a crystalline microstructure that meet the “first grain criteria”, defined below, and as measured using the OIM (Orientation Imaging Microscopy) sampling procedure, described below.
- the OIM analysis is to be completed through the full thickness of the sheet sample on the L-ST plane, using the OIM sample procedure, below.
- the size of the sample to be analyzed will generally vary by gauge.
- the OIM samples Prior to measurement, are prepared by standard metallographic sample preparation methods. For example, the OIM samples are metallographically prepared and then polished (e.g., using 0.05 micron colloidal silica). The samples are then anodized in Barker’s reagent, a diluted fluoroboric acid solution, for 90 seconds. The samples are then stripped using an aqueous phosphoric acid solution containing chromium trioxide, and then rinsed and dried.
- the software used is APEX EBSD Collection Software, Version 2 (ED AX Inc., New Jersey, U.S.A.), or equivalent, which is connected to a Velocity EBSD camera (ED AX Inc., New Jersey, U.S.A.), or equivalent.
- the SEM is an APREO S Field Emission Gun (Thermo Fisher Scientific. Waltham, MA, U.S.A.), or equivalent.
- OIM run conditions are 68° tilt with a 18 mm working distance and an accelerating voltage of 20 kV with dynamic focusing and an instrument-specified beam current of 51 nA (nanoamps).
- the mode of collection is hexagonal grid. A selection is made such that orientations are collected in the analysis (i.e., Hough peaks information is not collected).
- the area size per scan i.e., the frame
- the collected data is output in an *.osc file. This data may be used to calculate the volume fraction of first type grains, as described below.
- volume fraction of first type grains is calculated using the data of the *.osc file and the OIM Analysis Software (ED AX Inc., New Jersey, U.S.A.), version 8.1.0, or equivalent. Prior to calculation, two-step data cleanup may be performed. First, for any points whose confidence index is below a threshold of 0.08, a neighbor orientation correlation clean-up is performed. Second, a grain dilation clean-up is performed for any grain smaller than 3 data points. Then, the amount of first type grains is calculated by the software using the first grain criteria (below).
- GAM Grain average misorientation
- First grain volume means the volume fraction of first type grains of the crystalline material.
- the term “grain” has the meaning defined in ASTM El 12 ⁇ 3.2.2, i.e., “the area within the confines of the original (primary) boundary observed on the two-dimensional plane of-polish or that volume enclosed by the original (primary) boundary in the three-dimensional object”.
- A is the area of the individual grain as measured using commercial software OIM Analysis Software, version 8.1.0 or equivalent;
- A is the area of each individual grain as measured using commercial software OIM Analysis Software, version 8.1.0 or equivalent;
- d-bar is the area weighted average grain size.
- Texture means a preferred orientation of at least some of the grains of a crystalline structure.
- Texture components resulting from production of aluminum alloy products may include one or more of copper, S texture, brass, cube, and Goss texture, to name a few. Each of these texture components is defined in Table A, below.
- EBSD data for texture quantification are that same data that are generated as described above to determine “grain size” and “percent recrystallized.”
- the quantification of texture components present is done by the EBSD software, i.e. OIM Analysis Software, version 8.1.0 or equivalent.
- First step is to align the EBSD data from the L-ST plane into the more commonly used L-LT reference plane.
- Quantification of texture components present (Cube%, Goss%, Brass%, S%, Copper%) is to be determined as the number fraction of measured points assigned to a specific texture component. Points are assigned to a texture component if the misorientation angle deviates from the ideal orientation by less than 15 degrees. This number fraction is multiplied by 100 to find the percentage of each texture component in the sample. viii. Miscellaneous
- the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise.
- the term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.
- the meaning of “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise.
- the meaning of “in” includes “in” and “on”, unless the context clearly dictates otherwise.
- FIG. l is a graph illustrating properties of the Example 1 alloys versus conventional 6111 and 6013 alloys.
- FIG. 2 is a graph illustrating properties of the Example 2 alloys.
- FIGS. 3-8 are tables illustrating the results of Example 3.
- each alloy contained not greater than 0.03 wt. % of any one impurity, and where each alloy contained not greater than 0.10 wt. %, in total, of all impurities.
- Some of the homogenized ingots were hot rolled to 5.842 mm (0.230 inch) followed by cold rolling (without any intermediate anneal) by 66% to a final gauge of 2.007 mm (0.079 inch).
- Other ingots were hot rolled to 3.531 mm (0.139 inch) followed by cold rolling (without any intermediate anneal) by 43% to a final gauge of 2.007 mm (0.079 inch).
- the final gauge materials were then solution heat treated in-line at various conditions, as per Table 2, below. The materials were water spray quenched in-line after solution heat treatment.
- the alloys were artificially aged both with and without pre-strain (stretching) prior to the age. Specifically, the alloys were (i) aged at 185°C (365°F) for 20 minutes without any pre-strain (“Agel”), (ii) stretched 2% (pre-strained) and then aged at 185°C (365°F) for 20 minutes (“Age2”), and (iii) aged at 225°C (437°F) for 30 minutes without any pre-strain (“Age3”).
- the mechanical property results are shown in Tables 4-6, below. All properties are relative to the LT (long transverse) direction.
- Fracture behavior was also evaluated using three-point bending tests (as defined in the Definitions section), the test results of which are provided in Tables 7-8, below. These tests are used to assess, inter alia, a material’s (a) ability to be riveted without cracking and (b) behavior in crash situations. The tests were conducted relative to the transverse orientation (LT), and the reported values are based on the average of ten specimens used for each alloy tested. The properties are in relation to 1 -month naturally aged materials.
- the 6111 alloy is unable to achieve the strengths achieved by the invention alloys.
- the 6013 alloy is unable to achieve the high three- point bend properties achieved by the invention alloys.
- the microstructure of the invention alloy materials and the 6111 and 6013 materials were also assessed. Specifically, grain size, texture, dispersoid fraction, and percent recrystallization were determined in accordance with the Microstructure Assessment Procedure, included herein.
- the invention alloy has a higher area fraction of dispersoids than both 6111 and 6013, and both the invention alloy and 6111 have finer dispersoids than 6013, as shown in Table 12.
- the invention alloys also have a notably higher f/r value than the 6013 and 6111 alloys. In the f/r ratio, f is the fraction of dispersoids (Area %/l 00) and r is the average dispersoid radius (Diameter/2). A higher f/r tends to result in greater grain boundary pinning, also called Zener drag, which will tend to promote fine grain size.
- each alloy contained not greater than 0.03 wt. % of any one impurity, and where each alloy contained not greater than 0.10 wt. %, in total, of all impurities.
- the homogenized ingots were then hot rolled to 3.531 mm (0.139 inch) followed by cold rolling (without any intermediate anneal) by 43% to a final gauge of 2.007 mm (0.079 inch).
- the final gauge materials were then solution heat treated at 1040°F, water quenched, stretched for flatness, and then naturally aged for 7 days.
- the alloys were then either aged (i) according to “Age 3” per Example 1 (i.e., at 437°F (225°C) for 30 minutes) or (ii) at 356°F (180°C) for 8 hours (“Age 4”).
- the XA10 alloy realizes a very high combination of strength and fracture behavior (e.g., as shown in FIG. 2), which may be due to its manganese plus chromium content.
- the XA10 alloy realized a significantly lower amount of constituent particles (0.49%) compared to the other alloys (0.623 to 0.732%).
- XA08, XA10, XA11 and XA13 contain similar total amounts of Fe, Si, Cr and Mn, the elements which are incorporated in the constituent particles.
- the Example 2 alloys realize a similar texture to that of the invention alloy of Example 1, i.e., they contain notably high levels of the cube texture, which is the most desirable component for formability and fracture behavior.
- FIGS. 6-8 show the artificial aging results.
- the artificial aging condition was Agel, i.e., aged at 185°C (365°F) for 20 minutes without any pre-strain.
- the artificial aging occurred after the specified weeks or months of natural aging. (Note: the data for 1 month of natural aging in FIGS 3-8 are those already reported above in Example 1.)
- the inventive alloy’s properties are highly stable over the Time Test Period, which is important for automotive manufacturers because they can stock/store the invention alloys with confidence in shelf life.
- increases in tensile yield strength were less than 13MPa for all lots over the Test Time Period, i.e., as measured from the period starting after 2 weeks of natural aging (+/- 12 hours) and ending after
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PCT/US2022/014108 WO2022165044A2 (en) | 2021-01-29 | 2022-01-27 | New 6xxx aluminum alloys |
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US (1) | US20230374632A1 (en) |
EP (1) | EP4284955A2 (en) |
JP (1) | JP2024505008A (en) |
KR (1) | KR20230137348A (en) |
CA (1) | CA3205192A1 (en) |
MX (1) | MX2023008873A (en) |
WO (1) | WO2022165044A2 (en) |
Cited By (1)
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WO2024086389A3 (en) * | 2022-07-25 | 2024-07-18 | Novelis Inc. | High-strength corrosion-resistant 6xxx series aluminum alloys and methods for preparing the same |
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US9890443B2 (en) * | 2012-07-16 | 2018-02-13 | Arconic Inc. | 6XXX aluminum alloys, and methods for producing the same |
US10513766B2 (en) * | 2015-12-18 | 2019-12-24 | Novelis Inc. | High strength 6XXX aluminum alloys and methods of making the same |
ES2907839T3 (en) * | 2016-12-16 | 2022-04-26 | Novelis Inc | High-strength, highly-formable aluminum alloys resistant to natural age hardening and processes for making the same |
EP3676410B1 (en) * | 2017-10-23 | 2023-08-09 | Novelis Inc. | High-strength, highly formable aluminum alloys and methods of making the same |
KR102580687B1 (en) * | 2018-10-23 | 2023-09-21 | 노벨리스 인크. | Formable high-strength aluminum alloy products and methods for manufacturing the same |
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2022
- 2022-01-27 CA CA3205192A patent/CA3205192A1/en active Pending
- 2022-01-27 KR KR1020237026119A patent/KR20230137348A/en unknown
- 2022-01-27 JP JP2023544669A patent/JP2024505008A/en active Pending
- 2022-01-27 WO PCT/US2022/014108 patent/WO2022165044A2/en active Application Filing
- 2022-01-27 MX MX2023008873A patent/MX2023008873A/en unknown
- 2022-01-27 EP EP22746611.7A patent/EP4284955A2/en active Pending
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Cited By (1)
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WO2024086389A3 (en) * | 2022-07-25 | 2024-07-18 | Novelis Inc. | High-strength corrosion-resistant 6xxx series aluminum alloys and methods for preparing the same |
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US20230374632A1 (en) | 2023-11-23 |
EP4284955A2 (en) | 2023-12-06 |
WO2022165044A3 (en) | 2022-10-13 |
KR20230137348A (en) | 2023-10-04 |
MX2023008873A (en) | 2023-08-15 |
JP2024505008A (en) | 2024-02-02 |
CA3205192A1 (en) | 2022-08-04 |
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