WO2023076889A1 - Feuilles d'aluminium traitées thermiquement et procédés de fabrication - Google Patents

Feuilles d'aluminium traitées thermiquement et procédés de fabrication Download PDF

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Publication number
WO2023076889A1
WO2023076889A1 PCT/US2022/078643 US2022078643W WO2023076889A1 WO 2023076889 A1 WO2023076889 A1 WO 2023076889A1 US 2022078643 W US2022078643 W US 2022078643W WO 2023076889 A1 WO2023076889 A1 WO 2023076889A1
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Prior art keywords
metal strip
less
meters
abouto
alloy
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PCT/US2022/078643
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English (en)
Inventor
Alok Kumar Gupta
Jefferson LANSFORD
Charissa HICKSON
Farid TEBIB
Chadwick MORROW
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Novelis Inc.
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Priority to KR1020247006080A priority Critical patent/KR20240039158A/ko
Priority to CA3229084A priority patent/CA3229084A1/fr
Publication of WO2023076889A1 publication Critical patent/WO2023076889A1/fr

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    • 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
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium

Definitions

  • the present disclosure relates to metal processing generally and more specifically to continuous heat treatment processes for metals, where a strip of a heat treatable alloy is solutionized, rapidly cooled, thermally spiked, and coiled.
  • Heat-treatable metals such as heat-treatable aluminum alloys
  • Heat-treatable alloys are generally those containing soluble alloying constituents in amounts that exceed their room temperature solubility limits. These alloys can contain hardening elements (e.g., Mg, Si and/or Co) to provide hardening during aging, and potentially other elements, like Fe, Mn and possibly Cr, to control the formability and grain size. Such alloys may develop enhanced properties upon being subjected to working and/or heating, followed by a quenching step. Heat treatment of metals is traditionally performed by precipitation hardening involving the steps of solution heat treatment and aging.
  • a metal strip e.g., an aluminum alloy strip
  • the purpose of the solutionizing procedure is to take the alloying (solute) elements into solution, which will eventually strengthen the particular alloy.
  • the purpose of the rapid cooling is to lock the solute elements and excess vacancies into the metal (e.g. , aluminum) matrix of the metal strip.
  • the purpose of thermal spiking is to ensure that the coil is coiled between 60 °C to 110 °C and to eliminate the adverse effect of coil storage during which material loses potential strength gain during paint bake of up to 40%.
  • the heat treated metal strip can then undergo an aging procedure.
  • the current process to produce age tempers requires a batch ageing process where a coil in the T4 temper is heated at 20 °C/h to 50 °C/h to an elevated temperature ranging from 120 °C to 260 °C, soaked for >1 hour, and cooled to room temperature.
  • the existing thermal treatment and batch aging processes require total cycle times longer than 8 hours plus soak time (>1 hour, often 4-6 hours), added steps and complexity, and precise control over the heat treatment process.
  • Certain aspects and features of the present disclosure relate to a continuous heat treatment process, where a metal strip is solutionized, rapidly cooled, thermally spiked at an elevated temperature ranging from 120 °C to 300 °C (e.g., from 200 °C to 250 °C), and coiled at the rewind located at the end of the continuous line.
  • the continuous heat treatment process and its constituent steps can occur at a particular line speed, for example a line speed of at least 10 meters/min (e.g., at least 40 meters/min; from 10 meters/min to 100 meters/min, from 40 meters/min to 100 meters/min, or from 10 meters/min to 40 meters/min).
  • the thermal spike treatment can occur in a relatively long reheater furnace, for example a reheater furnace longer than 10 meters.
  • only natural cooling i.e., no cooling apparatus is used
  • the cooling or natural cooling rate after thermal spike treatment is less than 10 °C/hour (e.g., less than 2 °C/hour) down to ambient temperature, for example.
  • the coiling of the metal strip is performed at a relatively warm temperature, for example at a temperature above 60 °C, such as above 110 °C, from 70 °C to 150 °C, from 70 °C to 130 °C, or from 70 °C to 110 °C, from 110 °C to 150 °C, from 110 °C to 130 °C, or from 110 °C to 120 °C, for example.
  • the disclosed process does not include or need a batch aging process to age harden the material.
  • the present disclosure is able to produce a product from the disclosed proce ss with thin gauge that has both good formability and high strength using a continuous annealing line without requiring a batch ageing process.
  • the disclosure is particularly beneficial in terms of offering products with tailored combination of properties and hence offeringthe possibility of downgauging or as a potential substitute for 5000 series aluminum alloys supplied in HIX, H2X and H3x tempers.
  • Certain aspects and features of the present disclosure relate to a continuous heat treatment process, where a metal strip is solutionized, rapidly cooled, thermally spiked (e.g., by hot air) at an elevated temperature ranging from 120 °C to 300 °C, coiled, and cooled or naturally cooled (before and/or after coiling), for example at a rate of less than or equal to 5 °C/hour, preferably at a rate less than or equal to 2 °C/hour.
  • the metal strip is a heat treatable alloy, for example, a heat treatable aluminum alloy.
  • the thermal spike temperature is kept between 120 °C and 300 °C (e.g., from about 150 °C to 300 °C).
  • the use of thermal spike at higher temperature can induce the formation of clusters which act as nuclei to form hardening particles during subsequent coiling and coil cooling.
  • the present disclosure improves over existing technology in part by eliminating the batch process altogether by using a reheater furnace to thermally spike a metal strip to a desired temperature at the speed of the line before coiling.
  • a continuous annealing line can be used without requiring a batch aging process.
  • the thermally spiked coil in combination with coil cooling provides appropriate conditions for age hardening.
  • the use of thermal spiking and coiling at warm coiling temperatures to tailor a variety of properties is achieved by the present disclosure.
  • the disclosure is particularly beneficial in terms of offering products with tailored combination of properties and hence offeringthe possibility of downgauging.
  • aspects and features of the present disclosure are described herein with respect to metal strips, such as continuously-cast or uncoiled metal strips, however the present disclosure can also be used with any suitable metal products processed on a continuous annealing line.
  • the aspects and features of the present disclosure can be especially suitable for any metal product having flat surfaces.
  • the aspects and features of the present disclosure can be especially suitable for any metal product having parallel or approximately parallel opposing surfaces (e.g., top and bottom surfaces). Approximately parallel can include parallel or within 1°, 2°, 3°, 4°, 5°, 6°, 7°, 8°, 9°, or 10° of parallel, or more.
  • invention As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
  • 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
  • a shate 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 ? 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, or less than about 0.3 mm (e.g., about 0.2 mm).
  • a foil generally refers to a metal product having a thickness less than about 0.2 mm.
  • a foil may have a thickness of less than about 0.2 mm, less than about 0.15 mm, less than about 0.10 mm, less than about 0.05 mm, less than about 0.04 mm, less than about 0.03 mm, less than about 0.02 mm, or less than about 0.01 mm (e.g., about 0.006 mm).
  • DC direct chill
  • continuous casting are two methods of casting solid metal from liquid metal.
  • liquid metal is poured into a mold having a retractable false bottom capable of withdrawing at the rate of solidification of the liquid metal in the mold, often resultingin a large and relatively thick ingot (e.g. , 1500 mm wide x 500 mm thick x 5 m long).
  • the ingot can be processed, homogenized, hot rolled, cold rolled, may or may not be annealed after hot rolling or before a final cold rolling pass, and/or heat treated, and otherwise finished before being coiled into a metal strip product distributable to a consumer of the metal strip product (e.g., an automotive manufacturing facility).
  • Continuous casting involves continuously injecting molten metal into a casting cavity defined between a pair of moving opposed casting surfaces and withdrawing a cast metal form (e.g., a metal strip) from the exit of the casting cavity.
  • a cast metal form e.g., a metal strip
  • Continuous casting has been desirable in instances where the entire product can be prepared in a single, fully-coupled processing line.
  • Such a fully-coupled processing line involves matching, or “coupling,” the speed of the continuous casting equipment to the speed of the downstream processing equipment.
  • An F condition ortemper refers to an aluminum alloy as fabricated.
  • An O condition or temp er refers to an aluminum alloy after annealing.
  • An Hxx condition ortemper also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers.
  • a TI condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature).
  • a T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged.
  • a T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged.
  • a T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged.
  • a T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures).
  • a T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged.
  • a T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged.
  • a T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged.
  • a T9 condition ortemper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked.
  • a W condition or temper refers to an aluminum alloy after solution heat treatment.
  • room temperature can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about26 °C, about 27 °C, about28 °C, about29 °C, or about 30 °C.
  • ambient conditions can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mb ar.
  • relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 3 1%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 6
  • barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.
  • aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt.%). In each alloy, the remainder is aluminum, with a maximum wt.% of 0.15% for the sum of all impurities.
  • Incidental elements such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.
  • the heat treatment processes of the disclosure can be performed on a metal strip, e.g., an aluminum alloy strip.
  • the metal strip as described herein can be produced from casting a metal, e.g., DC casting or continuously casting a metal. After casting, in certain aspects, homogenizing, hot rolling, and/or cold rolling, and optional annealing after hot rolling or before the final cold rolling, can be performed to produce the metal strip.
  • the metal strip can be a metal sheet, shate, or foil.
  • the metal strip can be a sheet.
  • the described process is used to produce a sheet with a gauge from 0.5 mm to 4.5 mm.
  • the metal strip can be an aluminum alloy sheet, e.g., a heat treatable aluminum alloy sheet.
  • the metal strip can be selectedfrom a 2xxx series, a 6xxx series, or a 7xxx series aluminum alloy sheet.
  • the metal strip is a 2xxx series aluminum alloy sheet.
  • the metal strip is a 6xxx series aluminum alloy sheet.
  • the metal strip is a 7xxx series aluminum alloy sheet.
  • the metal strip can be a shate.
  • the metal strip can be an aluminum alloy shate, e.g. , a heat treatable aluminum alloy shate.
  • the metal strip can be selected from a 2xxx series, a 6xxx series, or a 7xxx series aluminum alloy shate. In some aspects, the metal strip is a 2xxx series aluminum alloy shate. In some aspects, the metal strip is a 6xxx series aluminum alloy shate. In some aspects, the metal strip is a 7xxx series aluminum alloy shate. In certain aspects, the metal strip can be a foil. In some aspects, the metal strip can be an aluminum alloy foil, e.g., a heat treatable aluminum alloy foil. In some aspects, the metal strip can be selected from a 2xxx series, a 6xxx series, or a 7xxx series aluminum alloy foil. In some aspects, the metal strip is a 2xxx series aluminum alloy foil. In some aspects, the metal strip is a 6xxx series aluminum alloy foil. In some aspects, the metal strip is a 7xxx series aluminum alloy foil.
  • the alloys exhibit high strength and high deformability . In some cases, the alloys exhibit an increase in strength after thermal treatment without significant loss of deformability. The properties of the alloys are achieved at least in part due to the methods of processingthe alloys to produce the described foils, shates, sheets or other products. [0030] In some examples, the alloys canhavethe following elemental composition as provided in Table 1.
  • the alloys canhavethe following elemental composition as provided in Table 2.
  • the alloys can have the following elemental composition as provided in Table 3.
  • an aluminum alloy can have the following elemental composition as provided in Table 4.
  • the alloy is used to prepare aluminum foils and sheets.
  • the disclosed alloy includes copper (Cu) in an amount from about 0.05 % to about 1.2 % (e.g., from about 0.1 % to about 1.2 %, from ab out 0.2 % to about 1.1 %, from about 0.3 % to about 1.0 %, from about 0.4 % to about 1.0 %, from about 0.6 % to about 1.1 %, from about 0.65 % to about 0.9 %, from about 0.7 % to about 1.0 %, or from about 0.6 %to about 0.7%) based on the total weight of the alloy.
  • Cu copper
  • the alloys can include about 0.05 %, about 0.06 %, about0.07%, about0.08 %, about 0.09 %, about 0.1 %, about 0.11 %, about 0.12 %, about 0.13 %, about 0.14 %, about 0.15 %, about 0.16 %, about 0.17%, about 0.18 %, about 0.19 %, about 0.2 %, about 0.21 %, about 0.22 %, about 0.23 %, about 0.24%, about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about 0.29 %, about 0.3 %, about 0.31 %, about 0.32 %, about 0.33 %, about 0.34 %, about0.35 %, aboutO.36%, aboutO.37%, about0.38 %, about0.39 %, about 0.4 %, about 0.41 %, about 0.42%, about 0.43 %, about 0.44%, about 0.45 %, about 0.46 %, about 0.41
  • the disclosed alloy includes silicon (Si) in an amount from about 0.6 % to about 1.5% (e.g., from about 0.7 % to about 1.3 %, from about 0.8 % to about 1.2 %, from about 0.9 % to about 1. 1 %, from about 0.6 % to about 0.9 %, from ab out
  • the alloys can include about 0.6 %, about 0.61 %, about 0.62 %, about 0.63 %, about 0.64 %, about 0.65 %, about 0.66 %, about 0.67 %, about 0.68 %, about 0.69 %, about 0.7 %, about 0.71 %, about 0.72 %, about 0.73 %, about 0.74 %, about 0.75 %, about 0.76 %, about 0.77 %, about 0.78 %, about 0.79 %, about 0.8 %, about 0.81 %, about 0.82 %, about 0.83 %, about 0.84 %, about 0.85 %, about 0.86 %, about 0.87 %, about 0.88 %, about 0.89 %, about 0.9 %, about 0.91 %, about 0.92 %, about 0.93 %, about 0.94 %, about 0.95
  • the disclosed alloy includes magnesium (Mg) in an amount from about 0.3 % to about 1.3 % (e.g., from about 0.4 % to about 1.25 %, from about 0.5 % to about 1.2 %, from about 0.7 % to about 1.1 %, from about 0.8 % to about 1 .25 %, from about 1.1 % to about 1 .25 %, from about 1.1 % to about 1 .2 %, f rom ab out 1 .0 % to about 1.2 %, from about 1.05 % to about 1 .3 %, or from about 1 .15 % to about 1 .3 %) b ased on the total weight of the alloy.
  • Mg magnesium
  • the alloys can include about 0.3 %, about 0.4 %, about 0.5 %, about 0.6 %, about 0.7 %, about 0.71 %, about 0.72 %, about 0.73 %, about 0.74 %, about 0.75 %, about 0.76 %, about 0.77 %, about 0.78 %, about 0.79 %, about 0.8 %, about 0.81 %, about O.82 %, about 0.83 %, about 0.84 %, about 0.85 %, about 0.86 %, about 0.87 %, about 0.88 %, about 0.89 %, about 0.9 %, about 0.91 %, about 0.92 %, about 0.93 %, about 0.94 %, about 0.95 %, about O.96 %, about 0.97 %, about 0.98 %, about 0.99 %, about 1 .0 %, about 1.01 %, about 1 .02 %, about 1 .03 %, about 1 .04 %, about 1
  • the alloy includes chromium (Cr) in an amount up to about 0.25 % (e.g., from about 0 % to about 0.25 %, from about 0.03 % to about 0.06 %, from about 0.03 % to about 0.19 %, or from about 0.06 % to about 0.1 %) based on the total weight of the alloy.
  • Cr chromium
  • the alloy can include about 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006%, about 0.007%, about 0.008 %, about 0.059 %, about 0.01 %, about 0.011 %, about 0.012 %, about 0.013 %, about 0.014 %, about 0.015 %, aboutO.016 %, about0.017 %, about0.018 %, aboutO.019%, about0.02 %, about 0.021 %, about 0.022 %, about 0.023 %, about 0.024%, about 0.025 %, about 0.026 %, about 0.027 %, aboutO.028 %, about0.029 %, about0.03 %, about0.031 %, aboutO.032 %, about 0.033 %, about 0.034 %, about 0.035 %, about 0.036%, about 0.037%, about 0.038
  • Cr is not present in the alloy (i.e., 0 %).
  • Cr can control grain structure and prevent grain growth and recrystallization. Higher amounts of Cr can provide a higher formability and improved bendability in aged temper.
  • the alloy can include manganese (Mn) in an amount up to about 0.35 % (e.g., from about 0 % to about 0.35 %, from about 0.05 % to about 0.18 %, from about 0.1 % to about 0.35 %, or from about 0.1 % to about 0.3 %) based on the total weight of the alloy.
  • Mn manganese
  • the alloy can include about 0.001 %, about 0.002 %, about 0.003 %, about 0.004%, about 0.005 %, about 0.006%, about 0.007%, about 0.008 %, about 0.059 %, about 0.01 %, about 0.011 %, about 0.012 %, about 0.013 %, about 0.014 %, about 0.015 %, about 0.016%, about 0.017 %, about 0.018 %, about 0.019%, about 0.02 %, about 0.021 %, about 0.022%, about 0.023 %, about 0.024%, about 0.025 %, about 0.026 %, about 0.027 %, aboutO.028 %, about0.029 %, about0.03 %, about0.031 %, aboutO.032 %, about 0.033 %, about 0.034%, about 0.035 %, about 0.036%, about 0.037%, about 0.038 %, about 0.039 %,
  • Mn is not present in the alloy (i.e., 0 %). All expressed in wt. %.
  • the alloy also includes iron (Fe) in an amount from about 0.1 % to about 0.35 % (e.g., from about 0.1 % to about 0.3 %, from about 0.1 % to about 0.25 %, from about0.18%to about0.25 %, from about0.2%to about0.21 %, or from about 0.15 % to about 0.22 %) based on the total weight of the alloy.
  • Fe iron
  • the alloy can include aboutO.l %, about0.ll %, about0.12 %, about0.13 %, aboutO.14%, aboutO.15 %, about 0.16 %, aboutO.17%, aboutO.18%, aboutO.19%, aboutO.2 %, aboutO.21 %, aboutO.22%, about 0.23 %, about 0.24%, about 0.25 %, about 0.26 %, about 0.27 %, about 0.28 %, about 0.29 %, or about 0.30 % Fe. In some cases, Fe is not present in the alloy (i.e., 0 %). All expressed in wt. %.
  • the alloy includes zirconium (Zr) in an amount up to about 0.25 % (e.g., from about 0 % to about 0.2 %, from about 0.01 % to about 0.25 %, from about 0.01 % to about 0.15 %, from about 0.01 % to aboutO.l %, or from about 0.02 % to about 0.09 %) based on the total weight of the alloy.
  • Zr zirconium
  • the alloy can include about 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006%, about 0.007 %, aboutO.008 %, aboutO.009%, aboutO.01 %, aboutO.02 %, aboutO.03 %, about0.04 %, about0.05 %, aboutO.06%, about0.07%, about0.08 %, aboutO.09 %, about 0.1 %, about 0.11 %, aboutO.12%, aboutO.13 %, aboutO.14%, aboutO.15 %, aboutO.16 %, about 0.17 %, about 0.18 %, about 0.19 %, about 0.2 %, about 0.21 %, about 0.22 %, about 0.23 %, about 0.24 %, or about 0.25 % Zr.
  • Zr is not present in the alloy (i.e., 0 %). All expressed in wt. %. In some examples, Zr can control grain structure and prevent grain growth and recrystallization. Higher amounts of Zr can provide a higher formability and improved bendability as well in T4 and aged temper.
  • the alloy described herein includes zinc (Zn) in an amount up to about 1.0 % (e.g., from about 0 % to about 1.0 %, from about 0.001 % to about 0.3 %, from about 0.005 % to about 0.09%, from about 0.004 % to about 0.3 %, from about 0.03 % to about 0.2 %, or from about 0.06% to about 0.1 %) based on the total weight of the alloy.
  • Zn zinc
  • the alloy can include about 0.001 %, about 0.002 %, about 0.003 %, about 0.004 %, about 0.005 %, about 0.006 %, about 0.007%, about 0.008%, about 0.009 %, about 0.01 %, aboutO.Oll %, aboutO.012%, about0.013 %, about0.014 %, about0.015 %, about 0.016 %, aboutO.017%, about0.018 %, aboutO.019%, about0.02 %, about0.021 %, about 0.022 %, about 0.023 %, about 0.024 %, about 0.025 %, about 0.026%, about 0.027 %, about 0.028 %, about 0.029%, about 0.03 %, about 0.04%, about 0.05 %, about 0.06 %, about 0.07 %, about 0.08 %, about 0.09 %, about 0.1 %, about 0.11 %, about 0.12 %, about 0.13
  • Zn is not present in the alloy (i.e., 0 %). All expressed in wt. %. In certain aspects, Zn can benefit forming, including bending and the reduction of bending anisotropy in foil, sheet, and shate products.
  • the alloy includes titanium (Ti) in an amount of upto about 0.3 % (e.g., from aboutO % to about0.3 %, from aboutO.Ol % to about0.25 %, from about 0.05 % to about 0.2 %, or up to about 0.1 %) based on the total weight of the alloy.
  • the alloy can include aboutO.Ol %, aboutO.Ol 1 %, aboutO.012%, aboutO.013 %, about0.014 %, aboutO.015 %, about0.016 %, aboutO.017 %, aboutO.018%, about0.019 %, about0.02 %, about0.025 %, aboutO.03 %, aboutO.035 %, about0.04 %, about 0.045 %, aboutO.05 %, aboutO.055 %,0.06%, aboutO.065 %, aboutO.07 %, about 0.075 %, about 0.08 %, about 0.085 %, about 0.09 %, about 0.095 %, about 0.1 %, about 0.11 %, about 0.12 %, aboutO.13 %, aboutO.14%, aboutO.15 %, aboutO.16 %, about 0.17 %, about 0.18 %, aboutO.19 %, about0.2 %, aboutO
  • the alloy includes nickel (Ni) in an amountup to about0.04 % (e.g., from 0 % to about 0.02 %, from about 0.01 % to about 0.03 %, from about 0.03 % to about 0.04 %) based on the total weight of the alloy.
  • the alloy can include about 0.001 %, about0.005%, aboutO.Ol %, aboutO.Oll %, about0.012 %, about0.013 %, about 0.014 %, about 0.015 %, about 0.016 %, about 0.017%, about 0.018%, about 0.019 %, about 0.02 %, about 0.021 %, about 0.022%, about 0.023 %, about 0.024 %, about 0.025 %, about 0.026 %, about 0.027%, about 0.028 %, about 0.029%, about 0.03 %, about 0.031 %, about 0.032 %, about 0.033 %, about 0.034 %, about 0.035 %, about 0.036%, about 0.037 %, about 0.038 %, about O.039 %, or about 0.04 % Ni. In certain aspects, Ni is not present in the alloy
  • the alloy compositions can further include otherminor elements, sometimes referred to as impurities, in amounts of about 0.05 % or below, about 0.04 % or below, about 0.03 % orbelow, about 0.02 % orbelow, or about O.Ol % orbelow each.
  • impurities may include, but are not limited to, V, Ga, Ca, Hf, Sr, Sc, Sn, or combinations thereof. Accordingly, V, Ga, Ca, Hf, Sr, Sc, or Sn may be present in an alloy in amounts of about 0.05 % or below, about 0.04 % or below, about 0.03 % or below, about 0.02 % or below, or about O.Ol % orbelow.
  • the sum of all impurities does not exceed about 0.15 % (e.g., 0.1 %). All expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.
  • Certain aspects and features of the present disclosure relate to a continuous heat treatment process, where a metal strip is solutionized, rapidly cooled, thermally spiked at an elevated temperature (for example, at a temperature ranging from 120 °C to 300 °C), and coiled, as described below.
  • the metal strip is a heat treatable alloy, for example, a heat treatable aluminum alloy.
  • the thermally spiked metal strip is cooled before or after coiling.
  • the thermally spiked metal strip is only naturally cooled before or after coiling.
  • the coil can be cooled (e.g, using a cooling fan(s)) after coiling at the end of the continuous heat treatment process.
  • the metal strip itself can be prepared from scalping, homogenizing, hot rolling, optionally batch annealing, and cold rolling a cast ingot.
  • the continuous heat treatment process canbe operated at a specific line speed.
  • the continuous heat treatment process can be operated at a line speed greater than 5 meters/min, e.g., greater than 10 meters/min, greaterthan 20 meters/min, greater than
  • Solutionizing can put into solution (e.g., aluminum solid solution) the desired amount of alloying elements that are present in a particular alloy.
  • the solutionizing step can comprise heatingthe metal strip (e.g., plate, shate, sheet, or foil) from room temperature to a temperature of from about 400 °C to about 590 °C (e.g.
  • the strip can soak at the temperature for a period of time.
  • the strip is allowed to soak for a time (e.g., up to approximately 5 minutes, from about 10 seconds to about 5 minutes inclusively, from about 1 second to about 3 minutes, or from about 5 seconds to about 5 minutes).
  • the strip can be soaked at the temperature (e.g., from about 525 °C to about 590 °C) for less than 20 seconds, less than 25 seconds, less than 30 seconds, less than 35 seconds, less than 40 seconds, less than 45 seconds, less than 50 seconds, less than 55 seconds, less than 60 seconds, less than 65 seconds, less than 70 seconds, less than 75 seconds, less than 80 seconds, less than 85 seconds, less than 90 seconds, less than 95 seconds, less than 100 seconds, less than 105 seconds, less than 110 seconds, less than 115 seconds, less than 120 seconds, less than 125 seconds, less than 130 seconds, less than 135 seconds, less than 140 seconds, less than 145 seconds, or less than 150 seconds, or less than 5 minutes, or anywhere in between.
  • the temperature e.g., from about 525 °C to about 590 °C
  • the solutionizing can be carried out in a continuous process, e.g., a continuous heat treatment line.
  • the continuous process e.g., continuous heat treatment line
  • the continuous process can have a specific line speed.
  • the solutionizing step is performed on a metal strip immediately after a hot rolling step and/or a cold rolling step. In other aspects, the solutionizing step is performed on a metal strip after (e.g., > 48 hour after) a hot rolling step and/or a cold rolling step. In certain aspects, the solutionizing step is performed after an annealing and cold rolling step.
  • the metal strip in order to lock the solute elements and excess vacancies into the metal (e.g., aluminum) matrix of the metal strip, the metal strip can be cooled very rapidly.
  • the metal strip after solutionizing, the metal strip can be rapidly cooled to reduce the temperature of the metal strip.
  • the transfer time from the solutionizing furnace into the cooling medium is very short (e.g., less than I s, less than 2 s, less than 3 s, less than 5 s, less than 10 s, less than 15 s, less than 20 s, less than 25 s, less than 30 s, less than 35 s, less than 40 s, less than 45 s, less than 50 s, less than 55 s, less than 1 min, less than 2 min, less than 3 nun, less than 4 min, less than 5 min, or less than 10 min ).
  • the time for transfer of the solution ized metal begins from the moment that the furnace door begins to open and goes to the point at which the aluminum alloy is completely immersed and submerged. If the transfer time exceeds the prescribed time limit, incomplete solutionizing can occur, which means nonuniform metallurgical and mechanical conditions of the particular alloy.
  • the metal strip can be cooled at a rate that can vary between about 1 °C/s to 400 °C/s in a rapid cooling step that is based on the selected gauge.
  • the rapid cooling rate can be from about 50 °C/s to ab out 375 °C/s, from about 60 °C/s to about 375 °C/s, from about 70 °C/s to about 350 °C/s, from about 80 °C/s to about 325 °C/s, from about 90 °C/s to about 300 °C/s, from about 100 °C/s to about 275 °C/s, from about 125 °C/s to about 250 °C/s, from about 150 °C/s to about 225 °C/s, from about 175 °C/s to about200 °C/s, from about 10 °C/s to about 125 °C/s, or from about 20 °C/s to about
  • the metal strip can be rapidly cooled to a temperature of less than 100 °C, e.g., less than 90 °C, less than 80 °C, less than 70 °C, less than 60 °C, less than 50 °C, less than 45 °C, less than 40 °C, less than 35 °C, less than 30 °C, less than 25 °C, less than 20 °C, less than 15 °C, from about 20 °C to about 80 °C, from about 20 °C to about 70 °C , from about 20 °C to about 60 °C, from about 25 °C to about 50 °C, from about 25 °C to about 40 °C, to about 20 °C, to about 25 °C, to about 30 °C, to about 35 °C, to about 40 °C, to about45 °C, orto about 50 °C.
  • a temperature of less than 100 °C e.g., less than 90 °C, less than 80
  • the metal strip can be rapidly cooled with a liquid (e.g., water) and/or a gas or another selected cooling medium.
  • a liquid e.g., water
  • the metal strip is rapidly cooled with air.
  • the metal strip can be rapidly cooled with water.
  • the metal strip can be subjected to a thermal spike treatment at elevated temperature.
  • the thermal spike temperature i.e., the peak temperature that the metal strip is exposed to, not necessarily the temperature of the metal strip itself
  • the thermal spike temperature is in the range of from about 100 °C to about 300 °C, e.g., from about 120 °C to about 300 °C, from about 150 °C to about 300 °C, from about 170 °C to about 280 °C, from about 180 °C to about 270 °C, from about 190 °C to about260 °C, from about 200 °C to about 250 °C, from about 210 °C to about 250 °C, from about 220 °C to about 250 °C, from about 220 °C to about 240 °C, about 200 °C, about 210 °C, about 220 °C, about
  • the metal strip itself reaches to within 100 °C of the thermal spike temperature, e.g., within 90 °C, within 80 °C, within 70 °C, within 60 °C, within 50 °C, within 40 °C, within 30 °C, within 20 °C, within 10 °C, within 5 °C, or within 1 °C.
  • the thermal spike treatment occurs after solutionizing and air coolingthe metal strip.
  • the thermal spike treatment can occur at the same processing line speed as the solutionizing and rapid cooling, e.g., as part of a continuous heat treatment process.
  • thermal spiking between 150 and 320 °C (for example, in a long reheater furnace) e.g., between about 150 and 300 °C, between about 180 and 300 °C, or between about 150 and 225 °C, followed by coiling and coil cooling forms some of the clusters and zones and enhances the precipitation process during coil cooling.
  • the period of time for which the temperature is maintained at the peak thermal spike temperature may range from zero to any time that is practical in the circumstances.
  • the thermal spike treatment occurs at the speed of the processing line of the continuous heat treatment process (for example in a long furnace).
  • the speed of the processing line and the speed of the thermal spike treatment can occur at a speed of f rom about 1 meter/min to about 120 meters/min, e.g., from about 2 meters/min to about 110 meters/min, from about 5 meters/min to about 100 meters/min, from about 10 meters/min to about 600 meters/min, from about 20 meters/min to about 500 meters/min, from about 25 meters/min to about 500 meters/min, from about 30 meters/min to about 400 meters/min, from about40 meters/min to about 350 meters/min, from about 50 meters/min to about 300 meters/min, or from about 100 meters/min to about 250 meters/min.
  • the period is usually from zero up to about 5 minutes, e.g., from about 1 sec to about 5 min, from ab out 2 sec to about 4 min, from about 3 sec to about 3 min, from about 5 sec to about 2 min, from about ? sec to about 1 min, or from about 10 sec to about 30 sec.
  • the thermal spike treatment is carried out at a heating rate of (i.e., the temperature of the metal strip increases at a rate) about 1 °C/min to about 50 °C/s (e.g., from about 1 °C/s to about 40 °C/s, from about 2 °C/s to about 40 °C/s, from about 3 °C/s to about 35 °C/s, from about 3 °C/s to about 30 °C/s, from about 5 °C/s to about 30 °C/s, from about 10 °C/s to about 25 °C/s, or from about 2 °C/s to about 10 °C/s).
  • a heating rate of i.e., the temperature of the metal strip increases at a rate
  • about 1 °C/min to about 50 °C/s e.g., from about 1 °C/s to about 40 °C/s, from about 2 °C/s to about 40 °C/s, from
  • the thermal spike treatment is performed in a reheater furnace, e.g., a continuous reheater furnace.
  • the thermal spike treatment is performed in a long reheater furnace.
  • the furnace can have an effective length of (i.e., a length that the metal strip is heated in a continuous process) of at least 10 meters, e.g., at least 20 meters, at least 25 meters, at least 30 meters, at least 40 meters, at least 50 meters, at least 60 meters, at least 70 meters, at least 80 meters, at least 90 meters, or at least 100 meters. Without limiting the disclosure, this may allow for an increased line speed and/or thermal spike time.
  • the metal strip does not undergo an aging process.
  • the thermal spike of the metal strip in combination with coiling of the metal strip and/or cooling of the metal strip can take the place of age hardening.
  • the metal strip can be cooled after the thermal spike treatment. In some aspects, this cooling can occur after coiling. In other aspects, this cooling can occur before coiling. And in some aspects, cooling can occur before and/or after coiling.
  • the metal strip can be air cooled, e.g., using at least one fan.
  • the metal strip is only naturally cooled (for example, duringthe passage of the strip between the thermal spike treatment and coiling), meaning that there is no apparatus or process used to cool the metal strip prior to coiling. For example, the metal strip might only be exposed to the ambient conditions (e.g., atthe line speed of the continuous heat treatment process) prior to coiling. In some aspects, the metal strip is only naturally cooled after coiling.
  • cooling e.g. only exposure to the ambient conditions prior to cooling
  • the cooling or natural cooling can be carried out until the metal strip reaches ambient temperature.
  • the metal strip and/or the coiled metal strip can be cooled or naturally cooled at a rate of less than or equal to about 60 °C/hour (e.g., less than or equal to about 50 °C/hour, less than or equal to about 40 °C/hour, less than or equal to about 30 °C/hour, less than or equal to about20 °C/hour, less than or equal to about 10 °C/hour, less than or equal to about 5 °C/hour, less than or equal to about 3 °C/hour, less than or equal to about 2.5 °C/hour, less than or equal to about 2 °C/hour, less than or equal to about 1.5 °C/hour, less than or equal to about 1 °C/hour, or less than or equal to about 0.8 °C/hour).
  • a rate of less than or equal to about 60 °C/hour e.g., less than or equal to about 50 °C/hour, less than or equal to about 40 °C/hour, less than or
  • the disclosed metal (e.g., alloy) strip compositions are products of disclosed methods.
  • alloy properties such as aluminum alloy properties, are partially determined by the formation of microstructures during the alloy’s preparation.
  • the method of preparation for an alloy composition may influence or even determine whether the alloy will have properties adequate for a desired application.
  • the metal (e.g., alloy) strip described herein can be cast into ingots using a casting method.
  • the casting process can comprise a Direct Chill (DC) casting process.
  • the casting process can comprise a continuous casting process.
  • the cast ingot can then be subjected to further processing steps.
  • the processing method includes scalping, homogenization, hot rolling, optional batch annealing, and cold rolling, prior to the aforementioned solutionizing, rapid cooling, thermal spike treatment, and coiling and subsequent cooling (e.g., fan cooling after coiling).
  • the homogenization step can involve a one-step homogenization or a two-step homogenization.
  • a one-step homogenization is performed where an ingot prepared from an alloy composition described herein is heated to attain a peak metal temperature (PMT) of about, or at least about, 500 °C (e.g., at least 520 °C, at least 530 °C, at least 540 °C, at least 550 °C, at least 560 °C, at least 570 °C, or at least 580 °C).
  • PMT peak metal temperature
  • the ingot can be heated to a temperature of from about 520 °C to about 580 °C, from about 530 °C to about 575 °C, from about 535 °C to about 570 °C, from about 540 °C to about 565 °C, from about 545 °C to about 560 °C, from about 530 °C to about 560 °C, or from about 550 °C to about 580 °C.
  • the heating rate to the peak metal temperature can be about 100 °C/hour or less
  • the heating rate to the peak metal temperature can be from about 10 °C/min to about 100 °C/min (e.g.
  • the ingot is then allowed to soak (i.e., held at the indicated temperature) for a period of time.
  • the ingot is allowed to soak for up to about 8 hours (e.g., from about 5 seconds to 8 hours, or from about 30 minutes to about 8 hours, inclusively).
  • the ingot can be soaked at a temperature of at least 500 °C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, or anywhere in between.
  • a two-step homogenization is performed where an ingot prepared from an alloy composition described herein is heated to attain a first temperature of about, or at least about, 480 °C to about 520 °C.
  • the ingot can be heated to a first temperature of about480 °C, 490 °C, 500 °C, 510 °C, or 520 °C.
  • the heating rate to the first temperature can be from about 10 °C/min to about 100 °C/min (e.g., about 10 °C/min to about 90 °C/min, about 10 °C/min to about 70 °C/min, about 10 °C/min to about 60 °C/min, from about 20 °C/min to about 90 °C/min, from about 30 °C/min to about 80 °C/min, from about 40 °C/min to about 70 °C/min, or from about 50 °C/min to about 60 °C/min).
  • °C/min e.g., about 10 °C/min to about 90 °C/min, about 10 °C/min to about 70 °C/min, about 10 °C/min to about 60 °C/min, from about 20 °C/min to about 90 °C/min, from about 30 °C/min to about 80 °C/min, from about 40 °C/min to about 70
  • the heating rate to the first temperature can be from about 10 °C/hourto about 100 °C/hour (e.g., about 10 °C/ hour to about 90 °C/ hour, about 10 °C/hourto about 70 °C/hour, about 10 °C/ hourto about 60 °C/ hour, from about 20 °C/ hour to about 90 °C/ hour, from about 30 °C/ hour to about 80 °C/ hour, from about 40 °C/ hourto about 70 °C/hour, or from about 50 °C/hourto about 60 °C/ hour).
  • °C/hourto about 100 °C/hour e.g., about 10 °C/ hour to about 90 °C/ hour, about 10 °C/hourto about 70 °C/hour, about 10 °C/ hourto about 60 °C/ hour, from about 20 °C/ hour to about 90 °C/ hour, from about 30 °C/ hour to about 80 °C/ hour, from about 40
  • the ingot is then allowed to soak for a period of time.
  • the ingot is allowed to soak for up to about 6 hours (e.g., from 5 seconds to 6 hours, or from 30 minutes to 6 hours, inclusively).
  • the ingot can be soaked at a temperature of from about 480 °C to about 520 °C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, or 6 hours, or anywhere in between.
  • the ingot can be further heated from the first temperature to a second temperature of greater than about 520 °C (e.g., greater than 520 °C, greater than 530 °C, greater than 540 °C, greater than 550 °C, greater than 560 °C, greater than 570 °C, or greater than 580 °C).
  • a second temperature of greater than about 520 °C (e.g., greater than 520 °C, greater than 530 °C, greater than 540 °C, greater than 550 °C, greater than 560 °C, greater than 570 °C, or greater than 580 °C).
  • the ingot can be heated to a second temperature of from about 520 °C to about 580 °C, from about 530 °C to about 575 °C, from about 535 °C to about 570 °C, from about 540 °C to about 565 °C, from about 545 °C to about 560 °C, from about 530 °C to about 560 °C, or from about 550 °C to about 580 °C.
  • the heating rate to the second temperature can be from about 10 °C/min to about 100 °C/min (e.g., from about20 °C/min to about 90 °C/min, from about 30 °C/min to about 80 °C/min, from about 10 °C/min to about 90 °C/min, from about 10 °C/min to about 70 °C/min, from about 10 °C/min to about 60 °C/min, from about 40 °C/min to about 70 °C/min, or from about 50 °C/min to about 60 °C/min).
  • °C/min e.g., from about20 °C/min to about 90 °C/min, from about 30 °C/min to about 80 °C/min, from about 10 °C/min to about 90 °C/min, from about 10 °C/min to about 70 °C/min, from about 10 °C/min to about 60 °C/min, from about 40 °
  • the heating rate to the second temperature can be from ab out 10 °C/hour to about 100 °C/hour (e.g., from about 10 °C/ hour to about 90 °C/ hour, from about 10 °C/ hourto about 70 °C/ hour, from about 10 °C/hourto about 60 °C/ hour, from about 20 °C/ hourto about 90 °C/hour, from about 30 °C/hourto about 80 °C/ hour, from about 40 °C/ hourto about 70 °C/ hour, or from about 50 °C/hourto about 60 °C/hour).
  • the ingot is then allowed to soak for a period of time.
  • the ingot is allowed to soak for up to about 6 hours (e.g., from 5 seconds to 6 hours, or from 30 minutes to 6 hours, inclusively).
  • the ingot can be soaked at a temperature of from about 520 °C to about 580 °C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, or 6 hours, or anywhere in between.
  • a hotrolling step can be performed.
  • the ingots are laid down and hot-rolled with an entry temperature range of about 380 °C to about 540 °C.
  • the entry temperature can be, for example, about 505 °C, 510 °C, 515 °C, 520 °C, 525 °C, 530 °C, 535 °C, or 540 °C.
  • the hot roll exit temperature can range from about230 °C to about 420 °C (e.g., from about330 °C to about370 °C).
  • the hotroll exit temperature can be about 255 °C, 260 °C, 265 °C, 270 °C, 275 °C, 280 °C, 285 °C, 290 °C, 295 °C, 300 °C, 305 °C, 310 °C, 315 °C, 320 °C, 325 °C, 330 °C, 335 °C, 340 °C, 345 °C, 350 °C, 355 °C, 360 °C, 365 °C, 370 °C, 375 °C, or 380 °C and can be combined with any of the above entry temperatures.
  • the ingot can be hot rolled to an about 2 mm to about 15 mm thick gauge (e.g., from about 5 mm to about 12 mm thick gauge), which is referred to as a shate.
  • the ingot can be hot rolled to an about 4 mm thick gauge, about 5 mm thick gauge, about 6 mm thick gauge, about 7 mm thick gauge, about 8 mm thick gauge, about 9 mm thick gauge, about 10 mm thick gauge, about 11 mm thick gauge, ab out 12 mm thick gauge, about 13 mm thick gauge, about 14 mm thick gauge, or about 15 mm thick gauge.
  • the ingot can be hot rolled to a gauge greater than 15 mm thick (i . e .
  • the ingot can be hot rolled to a gauge less than 4 mm (i.e., a sheet).
  • the hot rolled coil can be batch annealed in some cases before cold rolling in some aspects. It is also possible in certain embodiments that the annealing is carried out after a first cold pass or a second cold pass, before the final cold pass.
  • a cold rolling step can be performed following the hot rolling step.
  • the rolled product from the hot rolling step can be cold rolled to a sheet (e.g., below approximately 4.0 mm).
  • the rolled product is cold rolled to a thickness of 0.6 mm to 1.0 mm, 1.0 mm to 3.0 mm, or 3.0 mm to 4.0 mm.
  • the alloy is cold rolled to about 3.5 mm or less, 3 mm or less, 2.5 mm or less, 2 mm or less, 1.5 mm or less, or 1 mm or less.
  • the rolled product can be cold rolled to about 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, or 3.0 mm.
  • aspects of the above process can be used to produce metal strips as described. Further, as discussed, the metal strips can be processed usingthe disclosed continuous heat treatment processes to produce a heat treated article. In some aspects, the entire process to produce a metal strip and heattreatthe metal strip is continuous. The metal strip can be then be subjected to the described heat treatment process.
  • a direct chill cast ingot of an alloy containing 0.62 wt.% Mg, 0.75 wt.% Si, 0.21 wt.% Cu, 0.13 wt.% Mn, 0.2 wt.% Fe and 0.02 wt.% Ti was scalped, homogenized, hot and cold rolled to a final 0.9 mm gauge.
  • the cold rolled strip of coil (Example 1) was solution heat treated between 540 °C and 575 °C, rapidly cooled to below 50 °C, and thermally spiked in a furnace set at 220 °C in a continuous process where strip is travelling at 60 meters/min before coiling. There was no intentional (i.e., only natural) cooling in between thermal spiking and coiling at the end of the process.
  • the strip was sampled before coiling at a flying shear location of the line and after cooling on a finishing line.
  • Table 6 Compositions of Examples 2-5 in wt. %
  • the objective of this trial was to twofold: first, examine the effects of heating rate during thermal spiking via change in the line speeds (52 m/min vs 41 m/min) on the strength of AA6111 coils and, second, compare tensile properties of AA6111 with typical 5xxx alloys supplied in H3X tempers.
  • a pair of 2mm gauge cold rolled coils (Examples 9 and 10) of AA61 11 alloy containing 0.76 wt.% Cu, 0.74 wt.% Mg, 0.66 wt.% Si, 0.27 wt.% Fe and 0.74 wt.% Mn were solutionized between 520 to 560 °C, rapidly cooled below 50 °C, thermally spiked in a furnace at 250 °C before coiling at the end of the continuous process.
  • Coils of Examples 9 and 10 were heat treated at 52 meter/min and 41 meter/min, respectively. The samples obtained from each coil on a finishing line and tested using the ASTM samples in both as-is and T8X tempers. The results of this trial are summarized in Table 10.
  • T4 and T8X tempers Both coils processed at two line speeds showvery similar properties in both T4 and T8X tempers, suggesting no major effect on the tensile properties from change in line speeds ranging from 41 m/min to 52 m/min strip speed.
  • the higher strengths in T4 temper potentially could be used for structural parts offering downgauging possibility or eliminate postformed heat treatments.
  • Table 11 summarizes typical ASTM tensile properties of commonly used 5xxx alloys.
  • the YS, UTS and total elongations values range from 190 to 290 MPa and 230 and
  • a direct chilled cast ingot of AA6111 alloy containing 0.69 wt.% Mg, 0.57% wt.% Si, 0.51 wt.% Cu, 0.19 wt.% Mn, 0.23 wt.% Fe and 0.01 wt.% Ti was scalped, homogenized, hot and cold rolled to a final 2.3 mm gauge.
  • the cold rolled strip of coil was solution heat treated between 525 °C, rapidly cooled to below 50 °C, and thermally spiked in a furnace to heatup strip to about 190 °C in a continuous process and rewound in a coil wide sidewall temperature of about 135 °C.
  • the line speed was modulated between 17 to 20 meters/min to ensure strip temperature at the exit of the furnace close to 190 °C. There was no intentional cooling in between thermal spiking and coiling at the end of the process. The coil temperature decreased from 135 °C to 85°C at about 2.8 °C/h and further cooling to ambient would be less than 2 °C/hour.
  • the coil was sampled after 5 days of the heat treatment and tested using ASTM samples in as-is and different paint bake tempers.
  • Table 12 shows the average transverse ASTM tensile properties of the sheet sample taken from the coil cooled samples.
  • the yield strength (YS) and ultimate tensile strength (UTS) of the coil cooled sample are 277 and 344 Mpa respectively with a 17% total elongation value. These properties are significantly different from AA6111 coils normally produced with coiling temperatures below 100 °C, typically exhibiting 125 Mpa YS, 230 MPa UTS, and 24% total elongation.
  • the properties of the coil are characteristic of aged tempers obtained close to 50 h of ageing at 140 °C. Without being bound by theory, the thermal spiking is accelerating the hardening process during coil cooling.
  • the alloy shows marginal increase in strength if aged at elevated temperatures with and without prestrains as shown in Table 12.
  • the thermal spiking process produces coils with strength at relatively short ageing times and better elongations than expected from a typical batch annealing process with less than 14% elongation.
  • any reference to a series of embodiments is to be understood as a reference to each ofthose embodiments disjunctively (e.g., “Embodiments 1-4” is to be understood as “Embodiments 1, 2, 3, or 4”).
  • Embodiment 1 is a process for producing a heat treated aluminum alloy comprising casting a metal strip; solutionizing the cast metal strip at a line speed to produce a solutionized metal strip; air cooling the solutionized metal strip to produce a cooled metal strip; thermally spiking the cooled metal strip at a temperature from 150 °C to 300 °C continuously at the line speed to produce a thermally spiked metal strip; and coiling the thermally spiked metal strip to produce a coiled metal strip.
  • Embodiment 2 is the process of Embodiment 1, further comprising cooling the thermally spiked metal strip after thermally spiking.
  • Embodiment s is the process of any of the embodiments, wherein cooling the thermally spiked metal strip comprises air cooling the thermally spiked metal strip.
  • Embodiment 4 is the process of Embodiment 1, wherein only natural cooling occurs of the thermally spiked metal strip occurs between thermal spiking and coiling.
  • Embodiment 5 is the process of any of the embodiments, wherein coiling the thermally spiked metal strip is carried out continuously at the end of a continuous line.
  • Embodiment 6 is the process of any of the embodiments, wherein the cooling of the thermally spiked metal strip is at a rate of less than 10 °C/hour.
  • Embodiment 7 is the process of any of the embodiments, wherein the cooling of the thermally spiked metal strip is at a rate of less than 2 °C/hour.
  • Embodiment 8 is the process of any of the embodiments, wherein the coiling of the thermally spiked metal strip is at a temperature of 70 °C to 130 °C.
  • Embodiment 9 is the process of any of the embodiments, wherein the coiling of the thermally spiked metal strip is performed at a temperature above 60 °C.
  • Embodiment 10 is the process of any of the embodiments, wherein the line speed is at least 10 meters/min.
  • Embodiment 11 is the process of any of the embodiments, wherein the line speed is from 10 meters/min to 120 meters/min.
  • Embodiment 12 is the process of any of the embodiments, wherein the thermal spike temperature is from 150 °C to 280 °C.
  • Embodiment 13 is the process of any of the embodiments, wherein the thermal spike temperature is from 200 °C to 250 °C.
  • Embodiment 14 is the process of any of the embodiments, wherein casting a metal strip comprises continuous casting.
  • Embodiment 15 is the process of any of the embodiments, wherein casting a metal strip comprises Direct Chill (DC casting).
  • Embodiment 16 is the process of any of the embodiments, further comprising homogenizing, hot rolling, and cold rolling the metal strip after casting and before solutionizing.
  • Embodiment 17 is the process of any of the embodiments, wherein thermally spiking the cooled metal strip is carried out in a reheater furnace with a length of at least 12 meters.
  • Embodiment 18 is the process of any of the embodiments, wherein the solutionizing temperature is from about 480 °C to about 590 °C.
  • Embodiment 19 is the process of any of the embodiments, wherein air cooling the solutionized metal strip comprises cooling the solutionized metal strip to less than 50 °C.
  • Embodiment 20 is a heat treated metal strip formed from the process of any of the embodiments.

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Abstract

Est décrit dans la description un procédé de traitement thermique continu destiné à des métaux. Une bande d'un métal, par exemple d'un alliage pouvant être traité thermiquement, est mise en solution, refroidie rapidement, soumise thermiquement à des pics à haute température, et enroulée. Le procédé de traitement thermique continu n'implique pas, ni ne nécessite, un traitement de vieillissement discontinu.
PCT/US2022/078643 2021-10-26 2022-10-25 Feuilles d'aluminium traitées thermiquement et procédés de fabrication WO2023076889A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4808247A (en) * 1986-02-21 1989-02-28 Sky Aluminium Co., Ltd. Production process for aluminum-alloy rolled sheet
US5728241A (en) * 1993-07-28 1998-03-17 Alcan International Limited Heat treatment process for aluminum alloy sheet
WO2006005573A1 (fr) * 2004-07-09 2006-01-19 Corus Aluminium Nv Procede de production d'une matiere sous forme de feuille en alliage d'aluminium a reponse amelioree au durcissement par etuvage
US20180087122A1 (en) * 2016-09-27 2018-03-29 Novelis Inc. Pre-ageing systems and methods using magnetic heating

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4808247A (en) * 1986-02-21 1989-02-28 Sky Aluminium Co., Ltd. Production process for aluminum-alloy rolled sheet
US5728241A (en) * 1993-07-28 1998-03-17 Alcan International Limited Heat treatment process for aluminum alloy sheet
WO2006005573A1 (fr) * 2004-07-09 2006-01-19 Corus Aluminium Nv Procede de production d'une matiere sous forme de feuille en alliage d'aluminium a reponse amelioree au durcissement par etuvage
US20180087122A1 (en) * 2016-09-27 2018-03-29 Novelis Inc. Pre-ageing systems and methods using magnetic heating

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