WO2024054968A1

WO2024054968A1 - High recycle content aluminum alloys and methods of making and using

Info

Publication number: WO2024054968A1
Application number: PCT/US2023/073719
Authority: WO
Inventors: Zeqin LIANG; Guillaume Hubert FLOREY; Jonathan FRIEDLI; Géraldine BARMAN; Tudor PIROTEALA; Milan FELBERBAUM; Jean-Francois DESPOIS
Original assignee: Novelis Inc.
Priority date: 2022-09-09
Filing date: 2023-09-08
Publication date: 2024-03-14

Abstract

Aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys are disclosed. The disclosed alloys can be prepared using large amounts of recycled aluminum alloy content, such as up to 100% recycled content, or more. The disclosed aluminum alloys include amounts of iron, manganese, chromium, and/or silicon in excess of comparable aluminum alloys commonly made by alloying prime aluminum. Further, the disclosed alloys include ratios of a total amount of manganese and chromium to iron of greater than or about 0.60 or 0.70, which may contribute, at least partly, to desirable bending, forming, and surface properties and characteristics of metal products made using the aluminum alloys. The disclosed alloys can be used to prepare automotive and structural panels such that these products are generated using large amounts of recycled aluminum alloy content.

Description

HIGH RECYCLE CONTENT ALUMINUM ALLOYS AND METHODS OF MAKING AND USING

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/375,093, filed on September 9, 2022, which is hereby incorporated by reference in its entirety.

FIELD

[0002] The present disclosure relates to metallurgy generally and more specifically to aluminum alloys having high recycled content.

BACKGROUND

[0003] High-forming aluminum alloys are used in many different applications, particularly in applications where strength and durability are required. For example, 6xxx series aluminum alloys have been widely used in automobile applications, due to their superior combination of properties including strength-to-weight ratio, formability, weldability, and general corrosion resistance. 6xxx series aluminum alloys are commonly used for automotive structural and closure panel applications in place of steel. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials reduces the weight of the vehicle and allows for substantial improvements in its fuel economy. Even so, the use of currently available aluminum alloys in automotive applications poses certain challenges.

SUMMARY

[0004] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure 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 claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

[0005] Described herein are aluminum alloys and metal products generated using those aluminum alloys. In certain aspects, methods of preparing metal products are also described. In some examples, an aluminum alloy comprises Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.20 wt.% V. Aluminum may be present as a remainder in the aluminum alloy (e.g., an amount of the aluminum alloy besides any alloying elements and impurities). In some examples, the aluminum alloy comprises up to 0.05 wt.% each of any individual impurity and up to 0.25 wt.% of all impurities. Optionally, certain elements in the aluminum alloys described herein are included at particular concentrations relative to other elements in the aluminum alloys. In some examples, a ratio of a total amount of Mn and Cr to an amount of Fe in the aluminum alloy is greater than or about 0.6 or greater than or about 0.7, such as from 0.6 to 2.5, such as from 0.6 to 0.65, from 0.65 to 0.7, from 0.7 to 0.75, from 0.75 to 0.8, from 0.8 to 0.9, from 0.9 to 1.0, from 1.0 to 1.1, from 1.1 to 1.2, from 1.2 to 1.3, from 1.3 to 1.4, from 1.4 to 1.5, from 1.5 to 1.6, from 1.6 to 1.7, from 1.7 to 1.8, from 1.8 to 1.9, from 1.9 to 2.0, from 2.0 to 2.1, from 2.1 to 2.2, from 2.2 to 2.3, from 2.3 to 2.4, from 2.4 to 2.5, or more. In some examples, the aluminum alloy comprises a 6xxx series aluminum alloy. Optionally, at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

[0006] These concentrations and relationships between concentrations may provide for the ability to include relatively high amounts of recycled aluminum alloy content in the disclosed aluminum alloys, while still retaining useful and/or beneficial physical and mechanical characteristics in products generated using the aluminum alloys. In some examples, the aluminum alloy comprises up to 100% recycled aluminum alloy content (e.g., by weight). In some examples, the aluminum alloy comprises more than 20% recycled aluminum alloy content (e.g., by weight). Without limitation, the aluminum alloys described may include from 20% to 100% recycled aluminum alloy content (e.g., by weight), such as from 20% to 25%, from 25% to 30%, from 30% to 35%, from 35% to 40%, from 40% to 45%, from 45% to 50%, from 50% to 55%, from 55% to 60%, from 60% to 65%, from 65% to 70%, from 70% to 75%, from 75% to 80%, from 80% to 85%, from 85% to 90%, from 90% to 95%, or from 95% to 100%. [0007] In some examples, the aluminum alloys can contain Si in amounts from about 1 wt.% to 1.5 wt.%. For example, Si may be present in the aluminum alloy in amounts from 1.00 wt.% to 1.01 wt.%, from 1.01 wt.% to 1.02 wt.%, from 1.02 wt.% to 1.03 wt.%, from

1.03 wt.% to 1.04 wt.%, from 1.04 wt.% to 1.05 wt.%, from 1.05 wt.% to 1.06 wt.%, from

1.06 wt.% to 1.07 wt.%, from 1.07 wt.% to 1.08 wt.%, from 1.08 wt.% to 1.09 wt.%, from

1.09 wt.% to 1.10 wt.%, from 1.10 wt.% to 1.11 wt.%, from 1.11 wt.% to 1.12 wt.%, from

1.12 wt.% to 1.13 wt.%, from 1.13 wt.% to 1.14 wt.%, from 1.14 wt.% to 1.15 wt.%, from

1.15 wt.% to 1.16 wt.%, from 1.16 wt.% to 1.17 wt.%, from 1.17 wt.% to 1.18 wt.%, from

1.18 wt.% to 1.19 wt.%, from 1.19 wt.% to 1.20 wt.%, from 1.20 wt.% to 1.21 wt.%, from

1.21 wt.% to 1.22 wt.%, from 1.22 wt.% to 1.23 wt.%, from 1.23 wt.% to 1.24 wt.%, from

1.24 wt.% to 1.25 wt.%, from 1.25 wt.% to 1.26 wt.%, from 1.26 wt.% to 1.27 wt.%, from

1.27 wt.% to 1.28 wt.%, from 1.28 wt.% to 1.29 wt.%, from 1.29 wt.% to 1.30 wt.%, from

1.30 wt.% to 1.31 wt.%, from 1.31 wt.% to 1.32 wt.%, from 1.32 wt.% to 1.33 wt.%, from

1.33 wt.% to 1.34 wt.%, from 1.34 wt.% to 1.35 wt.%, from 1.36 wt.% to 1.37 wt.%, from

1.37 wt.% to 1.38 wt.%, from 1.38 wt.% to 1.39 wt.%, from 1.39 wt.% to 1.40 wt.%, from

1.40 wt.% to 1.41 wt.%, from 1.41 wt.% to 1.42 wt.%, from 1.42 wt.% to 1.43 wt.%, from

1.43 wt.% to 1.44 wt.%, from 1.44 wt.% to 1.45 wt.%, from 1.45 wt.% to 1.46 wt.%, from

1.46 wt.% to 1.47 wt.%, from 1.47 wt.% to 1.48 wt.%, from 1.48 wt.% to 1.49 wt.%, or from

1.49 wt.% to 1.50 wt.%.

[0008] In some examples, the aluminum alloys can contain Fe in amounts up to about 0.35 wt.% Fe. For example, Fe may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, from 0.09 wt.% to 0.10 wt.%, from 0.10 wt.% to 0.11 wt.%, from 0.11 wt.% to 0.12 wt.%, from 0.12 wt.% to 0.13 wt.%, from 0.13 wt.% to 0.14 wt.%, from 0.14 wt.% to 0.15 wt.%, from 0.15 wt.% to 0.16 wt.%, from 0.16 wt.% to 0.17 wt.%, from 0.17 wt.% to 0.18 wt.%, from 0.18 wt.% to 0.19 wt.%, from 0.19 wt.% to 0.20 wt.%, from 0.20 wt.% to 0.21 wt.%, from 0.21 wt.% to 0.22 wt.%, from 0.22 wt.% to 0.23 wt.%, from 0.23 wt.% to 0.24 wt.%, from 0.24 wt.% to 0.25 wt.%, from 0.25 wt.% to 0.26 wt.%, from 0.26 wt.% to 0.27 wt.%, from 0.27 wt.% to 0.28 wt.%, from 0.28 wt.% to 0.29 wt.%, from 0.29 wt.% to 0.30 wt.%, from 0.30 wt.% to 0.31 wt.%, from 0.31 wt.% to 0.32 wt.%, from 0.32 wt.% to 0.33 wt.%, from 0.33 wt.% to 0.34 wt.%, or from 0.34 wt.% to 0.35 wt.%. [0009] In some examples, the aluminum alloys can contain Cu in amounts up to about 0.25 wt.%. For example, Cu may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to

0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, from 0.09 wt.% to

0.10 wt.%, from 0.10 wt.% to 0.11 wt.%, from 0.11 wt.% to 0.12 wt.%, from 0.12 wt.% to

0.13 wt.%, from 0.13 wt.% to 0.14 wt.%, from 0.14 wt.% to 0.15 wt.%, from 0.15 wt.% to

0.16 wt.%, from 0.16 wt.% to 0.17 wt.%, from 0.17 wt.% to 0.18 wt.%, from 0.18 wt.% to

0.19 wt.%, from 0.19 wt.% to 0.20 wt.%, from 0.20 wt.% to 0.21 wt.%, from 0.21 wt.% to

0.22 wt.%, from 0.22 wt.% to 0.23 wt.%, from 0.23 wt.% to 0.24 wt.%, or from 0.24 wt.% to 0.25 wt.%. Cu may be optional.

[0010] In some examples, the aluminum alloys can contain Mn in amounts from about 0.05 wt.% to 0.25 wt.%. For example, Mn may be present in the aluminum alloy in amounts from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, from 0.09 wt.% to 0.10 wt.%, from 0.10 wt.% to 0.11 wt.%, from 0.11 wt.% to 0.12 wt.%, from 0.12 wt.% to 0.13 wt.%, from 0.13 wt.% to 0.14 wt.%, from 0.14 wt.% to 0.15 wt.%, from 0.15 wt.% to 0.16 wt.%, from 0.16 wt.% to 0.17 wt.%, from 0.17 wt.% to 0.18 wt.%, from 0.18 wt.% to 0.19 wt.%, or from 0.19 wt.% to 0.20 wt.%. [0011] In some examples, the aluminum alloys can contain Mg in amounts from about 0.2 wt.% to 0.60 wt.%. For example, Mg may be present in the aluminum alloy in amounts from 0.20 wt.% to 0.21 wt.%, from 0.21 wt.% to 0.22 wt.%, from 0.22 wt.% to 0.23 wt.%, from 0.23 wt.% to 0.24 wt.%, from 0.24 wt.% to 0.25 wt.%, from 0.25 wt.% to 0.26 wt.%, from 0.26 wt.% to 0.27 wt.%, from 0.27 wt.% to 0.28 wt.%, from 0.28 wt.% to 0.29 wt.%, from 0.29 wt.% to 0.30 wt.%, from 0.30 wt.% to 0.31 wt.%, from 0.31 wt.% to 0.32 wt.%, from 0.32 wt.% to 0.33 wt.%, from 0.33 wt.% to 0.34 wt.%, from 0.34 wt.% to 0.35 wt.%, from 0.35 wt.% to 0.36 wt.%, from 0.36 wt.% to 0.37 wt.%, from 0.37 wt.% to 0.38 wt.%, from 0.38 wt.% to 0.39 wt.%, from 0.39 wt.% to 0.40 wt.%, from 0.40 wt.% to 0.41 wt.%, from 0.41 wt.% to 0.42 wt.%, from 0.42 wt.% to 0.43 wt.%, from 0.43 wt.% to 0.44 wt.%, from 0.44 wt.% to 0.45 wt.%, from 0.45 wt.% to 0.46 wt.%, from 0.46 wt.% to 0.47 wt.%, from 0.47 wt.% to 0.48 wt.%, from 0.48 wt.% to 0.49 wt.%, from 0.49 wt.% to 0.50 wt.%, from 0.50 wt.% to 0.51 wt.%, from 0.51 wt.% to 0.52 wt.%, from 0.52 wt.% to 0.53 wt.%, from 0.53 wt.% to 0.54 wt.%, from 0.54 wt.% to 0.55 wt.%, from 0.55 wt.% to 0.56 wt.%, from 0.56 wt.% to 0.57 wt.%, from 0.57 wt.% to 0.58 wt.%, from 0.58 wt.% to 0.59 wt.%, or from 0.59 wt.% to 0.60 wt.%. [0012] In some examples, the aluminum alloys can contain Cr in amounts up to about 0.10 wt.%. For example, Cr may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, or from 0.09 wt.% to 0.10 wt.%. Cr may be optional.

[0013] In some examples, the aluminum alloys can contain Ni in amounts up to about 0.10 wt.% Ni. For example, Ni may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, or from 0.09 wt.% to 0.10 wt.%. Ni may be optional.

[0014] In some examples, the aluminum alloys can contain Zn in amounts up to about 0.20 wt.% Zn. For example, Zn may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, from 0.09 wt.% to 0.10 wt.%, from 0.10 wt.% to 0.11 wt.%, from 0.11 wt.% to 0.12 wt.%, from 0.12 wt.% to 0.13 wt.%, from 0.13 wt.% to 0.14 wt.%, from 0.14 wt.% to 0.15 wt.%, from 0.15 wt.% to 0.16 wt.%, from 0.16 wt.% to 0.17 wt.%, from 0.17 wt.% to 0.18 wt.%, from 0.18 wt.% to 0.19 wt.%, or from 0.19 wt.% to 0.20 wt.%. Zn may be optional.

[0015] In some examples, the aluminum alloys can contain Ti in amounts up to about 0.15 wt.% Ti. For example, Ti may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, from 0.09 wt.% to 0.10 wt.%, from 0.10 wt.% to 0.11 wt.%, from 0.11 wt.% to 0.12 wt.%, from 0.12 wt.% to 0.13 wt.%, from 0.13 wt.% to 0.14 wt.%, or from 0.14 wt.% to 0.15 wt.%. Ti may be optional.

[0016] In some examples, the aluminum alloys can contain V in amounts up to about 0.20 wt.% V. For example, V may be present in the aluminum alloy in amounts from 0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, or from 0.09 wt.% to 0.10 wt.%. V may be optional.

[0017] In some examples, Fe present in an aluminum alloy can combine with other elements to form Fe-containing intermetallic particles. For example, Fe can combine with other elements to form alpha phase Fe-containing intermetallic particles and/or beta phase Fe- containing intermetallic particles. In some cases, it may be desirable to control the amounts of different Fe-containing intermetallic particles or the ratio of different Fe-containing intermetallic particle amounts in an aluminum alloy or a metal product comprising the aluminum alloy. For example, in some cases, the aluminum alloy, a metal product made from or comprising the aluminum alloy, comprises more alpha phase Fe-containing intermetallic particles than beta phase Fe-containing intermetallic particles.

[0018] Also described herein are metal products, such as metal products comprising an aluminum alloy, such as those described herein. The disclosed metal products can be processed into any desirable shape or form. In specific examples, the metal product comprises an automotive body product. The disclosed metal products can be made using any suitable processing where the aluminum alloy is processed using various processing steps to generate the metal product. In some cases, the metal product is a rolled metal product. Optionally, the metal product is a dual-recrystallized metal product. The metal product can exhibit suitable properties, such as mechanical or physical properties or characteristics, which may be advantageous for various end uses or implementations.

[0019] In some examples, the metal product exhibits isotropic strain characteristics. For example, the metal product may exhibit a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater, such as from 0.6 to 1.0, from 0.60 to 0.65, from 0.65 to 0.70, from 0.70 to 0.75, from 0.75 to 0.80, from 0.80 to 0.85, from 0.85 to 0.90, from 0.90 to 0.95, or from 0.95 to 1.0. In some examples, the metal product exhibits an fl 5% bending factor along a transverse direction of from about 0.3 to 1.0, such as from 0.3 to 0.4, from 0.4 to 0.5, from 0.5 to 0.6, from 0.6 to 0.7, from 0.7 to 0.8, from 0.8 to 0.9, or from 0.9 to 1.0. The f-bending factor may be measured according to ASTM E290, where f=r/t for a given pre-straining, with r being the lowest radius of the bend without any surface visible cracks to an unaided eye and t being the sheet thickness after the straining. For example, fl 5% is the bending factor after pre-straining of 15% in the transverse direction. In some examples, the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10° to 60°, such as from 10° to 15°, from 15° to 20°, from 20° to 25°, from 25° to 30°, from 30° to 35°, from 35° to 40°, from 40° to 45°, from 45° to 50°, from 50° to 55°, or from 55° to 60°. In some examples, the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 pm, such as less than or about 0.10 pm, less than or about 0.15 pm, less than or about 0.20 pm, less than or about 0.25 pm, less than or about 0.30 pm, less than or about 0.35 pm, less than or about 0.40 pm, less than or about 0.45 pm, less than or about 0.50 pm, less than or about 0.55 pm, or less than or about 0.60 pm. In some examples, the metal product exhibits a yield strength of from about 90 MPa to about 130 MPa when in a T4 temper, such as from 90 MPa to 95 MPa, from 95 MPa to 100 MPa, from 100 MPa to 105 MPa, from 105 MPa to 110 MPa, from 110 MPa to 115 MPa, from 115 MPa to 120 MPa, from 120 MPa to 125 MPa, or from 125 MPa to 130 MPa. In some examples, the metal product exhibits a yield strength of from about 200 MPa to about 235 MPa when in a T6 temper, such as from 200 MPa to 205 MPa, from 205 MPa to 210 MPa, from 210 MPa to 215 MPa, from 215 MPa to 220 MPa, from 220 MPa to 225 MPa, from 225 MPa to 230 MPa, or from 230 MPa to 235 MPa. In some examples, the metal product exhibits an ultimate tensile strength of from about 195 MPa to about 270 MPa when in a T4 temper, such as from 195 MPa to 200 MPa, from 200 MPa to 205 MPa, from 205 MPa to 210 MPa, from 210 MPa to 215 MPa, from 215 MPa to 220 MPa, from 220 MPa to 225 MPa, from 225 MPa to 230 MPa, from 230 MPa to 235 MPa, from 235 MPa to 240 MPa, from 240 MPa to 245 MPa, from 245 MPa to 250 MPa, from 250 MPa to 255 MPa, from 255 MPa to 260 MPa, from 260 MPa to 265 MPa, or from 265 MPa to 270 MPa. In some examples, the metal product exhibits an ultimate tensile strength of from about 240 MPa to about 300 MPa when in a T6 temper, such as from 240 MPa to 245 MPa, from 245 MPa to 250 MPa, from 250 MPa to 255 MPa, from 255 MPa to 260 MPa, from 260 MPa to 265 MPa, from 265 MPa to 270 MPa, from 270 MPa to 275 MPa, from 275 MPa to 280 MPa, from 280 MPa to 285 MPa, from 285 MPa to 290 MPa, from 290 MPa to 295 MPa, or from 295 MPa to 300 MPa. In some examples, the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper, such as from 20% to 21%, from 21% to 22%, from 22% to 23%, from 23% to 24%, from 24% to 25%, from 25% to 26%, from 26% to 27%, from 27% to 28%, from 28% to 29%, or from 29% to 30%. In some examples, the metal product exhibits a uniform elongation of from 10% to 20% when in a T6 temper, such as from 10% to 11%, from 11% to 12%, from 12% to 13%, from 13% to 14%, from 14% to 15%, from 15% to 16%, from 16% to 17%, from 17% to 18%, from 18% to 19%, or from 19% to 20%.

[0020] In an aspect, methods are also described herein, such as methods of processing aluminum alloys and methods of producing metal products. In some examples, a method of this aspect comprises casting an aluminum alloy to generate a cast product, such as an aluminum alloy described herein; homogenizing the cast product to generate a homogenized product; hot rolling the homogenized product to generate a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product.

Optionally, an exit temperature of the hot rolling is no more than 400 °C. Optionally, the hot rolling achieves a thickness reduction between the homogenized product and the rolled product of 90% or more.

[0021] Optionally methods of this aspect further comprise subsequent to the hot rolling, subjecting the rolled product to a recrystallization process to generate a recrystallized product, such as where the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product. Optionally, in some example methods, the recrystallization process occurs between the hot rolling and the final cold rolling process. Optionally, methods of this aspect comprise subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, such as where the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

[0022] In some examples, the recrystallization process comprises annealing the rolled product at peak metal temperature of from 325 °C to 425 °C for up to 1 minute to generate a recrystallized product; and quenching the recrystallized product. Additional details of recrystallization processes and associated methods useful with the aluminum alloys described herein are described in U.S. Provisional Application No. 63/261,042, filed on September 9, 2021, which is hereby incorporated by reference in its entirety.

[0023] Optionally, methods of this aspect further comprise subjecting the metal product to a solutionizing process to generate a solutionized metal product. Optionally, methods of this aspect further comprise subjecting the metal product to an aging or artificial aging process to generate an aged metal product. Additional processing steps may be optionally used for processing the disclosed aluminum alloys to generate metal products.

[0024] Other objects and advantages will be apparent from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF THE FIGURES

[0025] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components. [0026] FIG. 1 provides a schematic overview of an example method for making a rolled aluminum alloy product.

[0027] FIG. 2 provides a schematic overview of a process for preparing aluminum alloy articles.

[0028] FIG. 3 shows measured grain size characteristics of various aluminum alloy samples.

[0029] FIG. 4 shows measured texture characteristics of various aluminum alloy samples. [0030] FIG. 5 shows measured yield strength of various aluminum alloy samples.

[0031] FIG. 6 shows measured ultimate tensile strength of various aluminum alloy samples.

[0032] FIG. 7 shows measured uniform elongation of various aluminum alloy samples. [0033] FIG. 8 shows measured total elongation of various aluminum alloy samples. [0034] FIG. 9 measured strain-hardening exponent for 5% strain for various aluminum alloy samples.

[0035] FIG. 10 shows measured strain-hardening exponent for 10-20% strain for various aluminum alloy samples.

DETAILED DESCRIPTION

[0036] Described herein are aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys. The disclosed alloys can be prepared using large amounts of recycled aluminum alloy content, such as up to 100% recycled content. The disclosed aluminum alloys include amounts of iron, manganese, chromium, and/or silicon in excess of comparable aluminum alloys commonly made by alloying prime aluminum. Further, the disclosed alloys include ratios of a total amount of manganese and chromium to iron of greater than or about 0.70, which may contribute, at least partly, to desirable bending, forming, and surface properties and characteristics of metal products made using the aluminum alloys. The disclosed alloys can be used to prepare automotive and structural panels such that these products are generated using large amounts of recycled aluminum alloy content.

[0037] Aluminum alloys used for recycling can contain a mixture or unknown amounts of various aluminum alloys. In some cases, contaminants can also be present in aluminum alloys used for recycling. For example, aluminum alloys used for recycling may correspond to scrap source aluminum, such as end of life automotive aluminum or industrial scrap source, such as remelt scrap ingot (RSI), extrusion profile, aluminum plate, brazing scrap, as well as casting alloy scrap.

[0038] By increasing the amount of recycled aluminum content that can be included in the aluminum alloys described herein while still retaining favorable physical and mechanical properties so that the aluminum alloys can be useful as metal products for particular applications (e.g., as body or structural panels), the energy requirements and carbon footprint for preparing the metal products can be significantly reduced. As examples, the alloys and processing techniques described herein are useful for generating aluminum alloy sheet metal, or other metal products, with desirable bending characteristics, strength characteristics, forming characteristics (e.g., isotropic forming properties), and the like.

[0039] The alloy known as AA6016 is commonly used in automotive or structural applications. In general, however, AA6016 is not prepared using large amounts of recycled aluminum. For example, the elemental limits on AA6016 are typically lower for certain elements (e.g., Fe) than are commonly found in recycled aluminum alloy material. Stated another way, adding amounts of recycled aluminum content to an aluminum alloy that is destined to become AA6016 may necessitate use of large amounts of prime aluminum to ensure that certain elements (e.g., Fe) are not included in excess of those limits defined by the AA6016 designation. Thus, when large amounts of recycled aluminum content are included in an aluminum alloy, the designation can be different from AA6016. When such alloy is processed according to techniques commonly used to prepare products using AA6016, the resultant products can have mechanical and physical characteristics different from those made using AA6016.

[0040] The alloys described herein, however, overcome these challenges by including certain elements (e.g., iron, manganese, chromium, and/or silicon) in particular amounts and/or ratios to still retain beneficial properties. Furthermore, by carefully controlling the ratio of certain elements (e.g., ratio of a total amount of manganese and chromium to iron), desirable properties (e.g., mechanical properties or physical properties) in aluminum alloy products can be achieved. Additionally, particular processing schemes, such as those employing a rapid, low temperature annealing process prior to cold rolling or in between cold rolling steps, can be used to impart desirable properties (e.g., bending properties, forming properties, strength properties, and/or surface characteristics) to the resultant aluminum alloy products. Definitions and Descriptions:

[0041] 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.

[0042] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “7xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0043] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, 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.

[0044] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0045] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, 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).

[0046] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked, and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0047] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0048] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C. As used herein, the meaning of “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 mbar. For example, 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 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, 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.

[0049] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt.%).

[0050] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0051] In the present disclosure, 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% or 0.25% for the sum of all impurities.

[0052] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the disclosed alloys 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.

[0053] Unavoidable impurities, including materials or elements may be present in an alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some alloys, as described, may contain no more than about 0.15 wt.% or 0.25 wt.% of any element besides the alloying elements, incidental elements, and unavoidable impurities.

Methods of Producing and Preparing the Alloys and Aluminum Alloy Products

[0054] The aluminum alloy products described herein can be prepare using suitable methods. For example, aluminum alloys may be cast, homogenized, hot-rolled using break- down mill following by tandem mill or using break-down mill only, cold-rolled, heat treated, formed, or the like to generate aluminum alloy products.

[0055] FIG. 1 provides an overview of an example method of making aluminum alloy products. The method of FIG. 1 begins at 105, where an aluminum alloy 106 is cast to form a cast aluminum alloy product 107, such as an ingot or other cast product. At 110, the cast aluminum alloy product 107 is homogenized to form a homogenized aluminum alloy product

111. At 115, the homogenized aluminum alloy product 111 is subjected to one or more hot rolling passes and/or one or more cold rolling passes to form a rolled aluminum alloy product

112, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy shate, or an aluminum alloy sheet. Optionally, the rolled aluminum alloy product 112 is subjected to additional processing steps, as described below, to form an aluminum alloy article.

[0056] The alloys described herein can be cast using any suitable casting method known to those of ordinary skill in the art. As a few non-limiting examples, the casting process can include a direct chill (DC) casting process, a fusion casting process, or a continuous casting (CC) process. For example, FIG. 1 depicts a schematic illustration of a DC casting process at 105, but other casting processes can be used. A continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0057] A cast aluminum alloy product, such as a cast ingot, cast slab, or other cast product, can be processed by suitable techniques described herein. Optionally, the processing steps can be used to prepare rolled aluminum alloy products, such as aluminum alloy sheets. Example optional processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, annealing, solution heat treatment, and pre-aging.

[0058] In a homogenization step, the cast aluminum alloy product is homogenized to form a homogenized aluminum alloy product. During homogenization, a cast product may be heated to a temperature ranging from about 400 °C to about 565 °C. For example, the cast product can be heated to a temperature of about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 510 °C, about 520 °C, about 530 °C, or about 540 °C up to 565 °C. The product may then be allowed to soak (i.e., held at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time for the homogenization step, including the heating and soaking phases, can be up to 72 hours. For example, the product can be heated up to 500 °C to 565 °C, and soaked, for a total time of up to 18 hours for the homogenization step. Optionally, the product can be heated to below 490 °C and soaked, for a total time of greater than 18 hours for the homogenization step. In some cases, the homogenization step comprises multiple processes. In some non-limiting examples, the homogenization step includes heating a cast product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, a cast product can be heated to about 465 °C for about 3.5 hours and then heated to about 480 °C for about 6 hours. In some cases, the homogenization process and casting process are combined as casting with in-situ homogenization.

[0059] The homogenized aluminum alloy product is subjected to one or more roll bonding passes and/or one or more hot rolling passes to form a rolled aluminum alloy product, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy shate, or an aluminum alloy sheet. A roll bonding process can be carried out in different manners. For example, a roll bonding process can include both hot rolling and cold rolling. Further, a roll bonding process can be a one-step process or a multi- step process in which the material is gauged down during successive rolling steps. Separate rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, and the like.

[0060] Prior to the start of hot rolling, the homogenized product can be allowed to cool to a temperature between 380 °C to 450 °C. For example, the homogenized product can be allowed to cool to a temperature of between 400 °C to 425 °C. The homogenized product can then be hot rolled at a temperature between 250 °C to 450 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 2 mm and 200 mm (e.g., 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between).

[0061] Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature between 300 °C to 535 °C. For example, the continuously cast product can be allowed to cool to a temperature of between 325 °C to 510 °C, from 350 °C to 485 °C, from 375 °C to 460 °C, or from 400 °C to 435 °C. The continuously cast products can then be hot rolled at a temperature between 300 °C to 450 °C, for example, to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm and 25 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is no more than 470 °C, no more than 450 °C, no more than 440 °C, or no more than 430 °C.

[0062] Cast, homogenized, or hot-rolled products can optionally be subjected to a break down process or a break down and tandem process. Optionally, a cold rolling process may be used after a hot rolling process , a break down process, and or a break down and tandem process . The cold rolling process can use cold rolling mills to cold roll the aluminum product into thinner products, such as a cold rolled sheet. The cold rolled product can have a gauge between about 0.1 to 7 mm, e.g., between about 0.7 to 6.5 mm. Optionally, the cold rolled product can have a gauge of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm. The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to 95% (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 55%, up to 60%, up to 70%, up to 75%, up to 80%, or up to 85%, or up to 90%, up to 95%, or up to 99% reduction) as compared to a gauge prior to the start of cold rolling.

[0063] Following cold rolling process, an intermediate annealing process can be optionally used. In some cases, a product after a hot rolling process, a breakdown process, and/or a breakdown/tandem process is subjected to an intermediate annealing process. The intermediate annealing process can be any suitable treatment which results in at least partial recrystallization to generate a recrystallized aluminum product. The intermediate annealing process can comprise subjecting an unrecrystallized aluminum product (e.g., a hot-rolled product or a cold-rolled product) to a heat treatment at a predefined temperature of less than or equal to 495 °C for a length of time less than or equal to 25 minutes to generate a recrystallized aluminum product. For example, the cast, homogenized, hot rolled, or cold rolled product can be heated to a temperature of up to 495 °C for a length of time up to 25 minutes as part of an intermediate annealing process. In some examples, the temperature may be from about 300 °C to about 495 °C, such as from 300 °C to 305 °C, from 305 °C to 310 °C, from 310 °C to 315 °C, from 315 °C to 320 °C, from 320 °C to 325 °C, from 325 °C to 330 °C, from 330 °C to 335 °C, from 335 °C to 340 °C, from 340 °C to 345 °C, from 345 °C to 350 °C, from 350 °C to 355 °C, from 355 °C to 360 °C, from 360 °C to 365 °C, from 365 °C to 370 °C, from 370 °C to 375 °C, from 375 °C to 380 °C, from 380 °C to 385 °C, from 385 °C to 390 °C, from 390 °C to 395 °C, from 395 °C to 400 °C, from 400 °C to 405 °C, from 405 °C to 410 °C, from 410 °C to 415 °C, from 415 °C to 420 °C, from 420 °C to 425 °C, from 425 °C to 430 °C, from 430 °C to 435 °C, from 435 °C to 440 °C, from 440 °C to 445 °C, from 445 °C to 450 °C, from 450 °C to 455 °C, from 455 °C to 460 °C, from 460 °C to 465 °C, from 465 °C to 470 °C, from 470 °C to 475 °C, from 475 °C to 480 °C, from 480 °C to 485 °C, from 485 °C to 490 °C, from 490 °C to 495 °C, or from 490 °C to 495 °C. In some examples, the temperature may be from 320 °C to 495 °C, from 340 °C to 485 °C, from 350 °C to 475 °C, or from 370 °C to 475 °C. Any suitable temperature ramp rates may be used to heat up to and or cool down from the specified temperature. In some examples, the product is heated to the temperature for a length of time from about 0.1 seconds to about 25 minutes, such as from 0.1 seconds to 0.5 seconds, from 0.5 seconds to 1 second, from 1 second to 2 seconds, from 2 seconds to 3 seconds, from 3 seconds to 4 seconds, from 4 seconds to 5 seconds, from 5 seconds to 10 seconds, from 10 seconds to 15 second, from 15 seconds to 30 seconds, from 30 seconds to 45 seconds, from 45 seconds to 60 seconds, from 60 seconds to 75 seconds, from 75 seconds to 90 seconds, from 90 seconds to 105 seconds, from 105 seconds to 2 minutes, from 2 minutes to 3 minutes, from 3 minutes to 4 minutes, from 4 minutes to 5 minutes, from 5 minutes to 10 minutes, from 10 minutes to 15 minutes, from 15 minutes to 20 minutes, or from 20 minutes to 25 minutes. In some cases, this may indicate that the temperature is held at or about a specified temperature or within 5 °C or within 10 °C of the specified temperature for the length of time. In some examples, the temperature or temperature range may be paired with a specific length of time or time range. For example, the temperature may be from 340 °C to 485 °C while the length of time is less than or equal to 10 minutes, the temperature may be from 350 °C to 475 °C while the length of time is less than 1 minute, or the temperature may be from 370 °C to 475 °C while the length of time is from 2 seconds to 35 seconds. Any variation or combination of the above- mentioned temperatures and lengths of time may be used, and certain alloys or end product configurations may benefit from a particular temperature and length of time combination or range of particular temperatures and lengths of time.

[0064] The intermediate annealing process can include passing a cast, homogenized, or rolled product through a furnace at a speed from about 10 m/min to about 150 m/min, such as from 10 m/min to 15 m/min, from 15 m/min to 20 m/min, from 20 m/min to 25 m/min, from 25 m/min to 30 m/min, from 30 m/min to 40 m/min, from 40 m/min to 45 m/min, from 45 m/min to 50 m/min, from 50 m/min to 60 m/min, from 60 m/min to 70 m/min, from 70 m/min to 80 m/min, from 80 m/min to 90 m/min, from 90 m/min to 100 m/min, from 100 m/min to 110 m/min, from 110 m/min to 120 m/min, from 120 m/min to 130 m/min, from 130 m/min to 140 m/min. or from 140 m/min to 150 m/min. In some instances, the intermediate annealing process can include heating the cast, homogenized, or rolled product by passing the product through a gas-fired furnace. In some instances, the intermediate annealing process can include or use a magnetic heating unit with a heating rate of from 10 °C/s to 150 °C/s. Optionally, the intermediate annealing process can include or use a quenching process (e.g., a water quench or an air quench) with a cooling rate of from 5 °C/s to 150 °C/s, or more, to return the product to ambient or room temperature. Cold rolling the product after the intermediate annealing process may result in an unrecrystallized aluminum product with deformed grains. Cold rolling can be performed to create a final gauge thickness that represents a gauge reduction from 25% to 99% (e.g., from 25% to 30%, from 30% to 35%, from 35% to 40%, from 40% to 45%, from 45% to 50%, from 50% to 55%, from 55% to 60%, from 60% to 65%, from 65% to 70%, from 70% to 75%, from 75% to 80%, from 80% to 85%, from 85% to 90%, from 90% to 95%, or from 95% to 99% reduction) as compared to the gauge prior to cold rolling. In some specific examples, a cold rolling process may achieve a cold reduction from 55% to 75%, from 25% to 90%, from 45% to 95%, or from 60% to 99%.

[0065] Subsequently, the product can optionally undergo one or more solution heat treatment steps. The solution heat treatment steps can be any suitable treatment for the metal product which results in solutionizing of the soluble particles. As examples, the product can be heated to a peak metal temperature (PMT) of up to 590 °C (e.g., from 400 °C to 590 °C) and soaked for a period of time at the PMT to form a hot product. For example, the product can be soaked at 480 °C for a soak time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes). After heating and soaking, the hot product is rapidly cooled at rates greater than 90 °C/s to a temperature between 500 °C and room temperature to form a heat-treated product.

[0066] After quenching, the heat-treated product can optionally undergo a pre-aging treatment by reheating before coiling. The pre-aging treatment can be performed at a temperature of from about 50 °C to about 125 °C for a period of time of up to 6 hours. For example, the pre-aging treatment can be performed at a temperature of about 50 °C, about 55 °C. about 60 °C, about 65 °C, about 70 °C, about 75 °C, about 80 °C, about 85 °C, about 90 °C, about 95 °C, about 100 °C, about 105 °C, about 110 °C, about 115 °C, about 120 °C, or about 125 °C. Optionally, the pre-aging treatment can be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The pre-aging treatment can be carried out by passing the heat-treated product through a heating device, such as a device that emits radiant heat, convective heat, induction heat, infrared heat, or the like.

[0067] FIG. 2 provides a plot showing example temperatures of a cast metal product during various stages of a manufacturing process in accordance with various aspects of the present disclosure. As part of an initial casting stage 205, where molten metal is formed into an ingot, cast article, or other solid object or metal product, the molten metal may be cooled and/or solidified by a process involving quenching or cooling the metal by exposing the metal to water or an aqueous solution, such as in a direct chill casting process or in a continuous casting process that includes quenching immediately after casting.

[0068] Following the casting stage 205, the metal product may be subjected to a homogenization process 210, where the metal is heated to a temperature less than the melting or solidus temperature of the metal. Optionally, the metal product is heated to a temperature at which the base metal and any alloying elements form a solid solution.

[0069] Following the homogenization process 210, the metal product may be exposed to one or more processes that may, for example, form desirable microcrystalline structures within the metal product while elongating the metal product. Such processes may correspond to hot rolling 215 and/or cold rolling 220, for example, such as to form shates, plates, or sheets from a metal ingot or other cast article or metal product.

[0070] In some embodiments, exposing a metal product at an elevated temperature to a solution, such as water, an aqueous solution, or a gas, gas mixture, or gas-phase solution, in a quenching or cooling process may be used to reduce the temperature of the metal product to a temperature desirable or useful for a subsequent process. For example, exposing the metal product to water or an aqueous solution may be useful for cooling the metal product between hot rolling process 215 and subsequent processing. Tandem and/or breakdown processing is not shown in FIG. 2 but can be performed at any suitable temperature for such processes.

[0071] Following the hot rolling process 215 and/or the cold rolling process 220 (cold rolling process 220 may be optional), the metal product may be subjected to an intermediate annealing heat treatment process 225, where the metal product is heated to and held at a predefined temperature for a length of time less than or equal to an hour to generate at least partial recrystallization of the metal product. The metal product may be optionally subjected to an additional cold rolling process 230 after the intermediate annealing heat treatment process 225. Various different peak temperatures may be used for the intermediate annealing heat treatment process 225, as shown in FIG. 2, which may be dependent on the particular alloy of the metal product and/or the particular mechanical or physical properties desired for the final product, for example.

[0072] The metal product may then be subjected to a solution heat treatment process 235, where the temperature of the metal product is increased to a temperature above a threshold temperature, such as a temperature at which precipitated components in the metal product dissolve into a solid solution or a temperature at which recrystallization processes occur, and held at or above the threshold temperature for a period of time. At the end of the solution heat treatment process 235, the metal product may be subjected to a quenching process 240, where dissolved components are fixed into place by rapidly reducing the temperature of the metal by a quenching process. Such a quenching process 240 may involve exposing the metal product to a solution, such as a quench solution including water, an aqueous solution, or a gas or gas mixture.

[0073] In embodiments, the processes overviewed in FIG. 2 may be performed discretely or as part of one or more continuous processing lines where metal product may be transported as a coil, a film, or a web of material between processing stages. The metal product may be transported between stages by rolling the metal product, which may be under tension, over or between one or more rollers, or by transporting the metal product on one or more conveyors, for example. In addition, other stages not explicitly identified may be included before, between, and/or after any stage identified in FIG. 2. Other example stages include, but are not limited to, a tandem and/or breakdown stage, a washing stage, a chemical treatment stage, or a finishing stage. As examples, a finishing stage may correspond to a surface anodizing stage, a powder coating stage, a painting stage, a printing stage, or the like.

Methods of Using the Disclosed Aluminum Alloy Products

[0074] The aluminum alloy products described herein can be used in automotive applications and other transportation applications, including aircraft and railway applications. For example, the disclosed aluminum alloy products can be used to prepare automotive structural parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C -pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.

[0075] The aluminum alloy products and methods described herein can also be used in electronics applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the aluminum alloy products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis, and other portable electronics.

Methods of Treating Metals and Metal Alloys

[0076] Described herein are methods of treating and using metals and metal alloys, including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, among others, and the resultant treated metals and metal alloys. In some examples, the metals for use in the methods described herein include aluminum alloys, for example, Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys. In some examples, material comprising Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys are useful as recycled source content material for the aluminum alloys and metal products described herein. In some examples, the materials for use in the methods described herein include non-ferrous materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium- based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal or combination of materials. Monolithic as well as non-monolithic, such as roll-bonded materials, cladded alloys, clad layers, composite materials, such as but not limited to carbon fiber-containing materials, or various other materials are also useful with the methods described herein. In some examples, aluminum alloys containing iron are useful with the methods described herein.

[0077] By way of non-limiting example, exemplary Ixxx series aluminum alloys for use in the methods described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0078] Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein can include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0079] Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065. [0080] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0081] Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0082] Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, AA6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0083] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0084] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0085] The examples disclosed herein will serve to further illustrate aspects of the invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications, and equivalents thereof, which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention. The examples and embodiments described herein may also make use of conventional procedures, unless otherwise stated. Some of the procedures are described herein for illustrative purposes.

EXAMPLE 1

[0086] Samples of an aluminum alloy sheet metal were prepared by casting, homogenizing, hot rolling, cold rolling, solutionizing, and aging an aluminum alloy. Conventional DC casting techniques were used to prepare ingots comprising AA6016. The aluminum alloy contained about 55% recycled aluminum content. The aluminum alloy contained about 0.23-0.30 wt.% Fe, 0.15-0.20 wt.% Mn and 0.009-0.025 wt.% Cr, such that the ratio of Mn+Cr to Fe was about 0.67-0.73.

[0087] The ingots were homogenized at about 540 °C for about 14 hours. The homogenized products were subjected to hot rolling, followed by cold rolling, followed by solutionizing, according to conventional hot rolling, cold rolling, and solution heat treatment techniques. An exit temperature after hot rolling was 405 °C. The thickness reduction achieved by hot rolling was about 98% and the thickness reduction achieved by cold rolling prior to inter-annealing at 355 °C was 63%. Additional cold rolling was then used to generate a final gauge of 1.02 mm for the cold rolled product. The cold rolled product was subjected to a short (< 1 minute) solutionizing treatment at a peak metal temperature between 560 °C and 570 °C. Samples of the solutionized product were subjected to natural aging to achieve a T4 temper and these samples were subjected to testing for evaluation of properties. Some aged samples were also subjected to artificial aging to achieve a T6 temper and these samples were also subjected to testing for evaluation of properties. Measured values are shown in Tables 1 and 2. Roping characteristics (Sa and VDA 239-400 RK 10%) were also evaluated, with measured values shown in Table 3.

Table 1. T4 temper values

Table 2. T6 temper values

Table 3. Roping values

EXAMPLE 2

[0088] Samples of an aluminum alloy sheet metal were prepared by casting, homogenizing, hot rolling, cold rolling, and interannealing recrystallization an aluminum alloy. Conventional DC casting techniques were used to prepare ingots comprising AA6016. The aluminum alloy contained about 55% recycled aluminum content. The aluminum alloy contained about 0.23-0.30 wt.% Fe, 0.15-0.20 wt.% Mn and 0.009-0.025 wt.% Cr, such that the ratio of Mn+Cr to Fe was about 0.67-0.73.

[0089] The ingots were homogenized at about 540 °C for about 13-14 hours. The homogenized products were subjected to hot rolling, followed by cold rolling to a gauge of about 3.5 mm, followed by an interannealing recrystallization, followed by cold rolling to a final gauge of about 1.0 mm. Conventional hot rolling and cold rolling techniques were used. An exit temperature after hot rolling was about 350 °C, which generated fine precipitates in the samples. Several different interannealing recrystallization techniques were applied to samples of the product after hot rolling and cold rolling. Some of the samples were subjected to a solutionizing heat treatment and natural aging process following the final cold rolling to a T4 temper condition and properties were evaluated (e.g., grain characteristics, mechanical properties, crystal texture, surface character, etc.). Comparative samples of a different alloy (AA6016) including no recycled content (Cl) and of the same alloy (C2) were also evaluated for comparison where the same hot and cold rolling processes were used but no interannealing recrystallization treatment was used.

[0090] The first and second interannealing recrystallization techniques (RX1 and RX2) included heating the samples to 350 °C for 5 seconds, followed by air quenching. The third interannealing recrystallization technique (RX3) included heating the samples to 365 °C for 5 seconds using a magnetic induction heating system, followed by water quenching. The fourth interannealing recrystallization technique (RX3) included heating the samples to 415 °C for 5 seconds using a magnetic induction heating system, followed by water quenching. [0091] Full recrystallization of the samples was observed for all the tested interannealing recrystallization techniques. The grain growth observed in the first and second interannealing recrystallization techniques was different from that in the third and fourth interannealing recrystallization techniques, but no significant particle coarsening was observed in any of the interannealing recrystallization techniques.

[0092] FIG. 3 shows grain size characteristics of the various aluminum alloy samples. FIG. 4 shows texture characteristics of the various aluminum alloy samples. FIG. 5 shows yield strength of the various aluminum alloy samples. FIG. 6 shows ultimate tensile strength of the various aluminum alloy samples. FIG. 7 shows uniform elongation of the various aluminum alloy samples. FIG. 8 shows total elongation of the various aluminum alloy samples. FIG. 9 strain-hardening exponent for 5% strain for the various aluminum alloy samples. FIG. 10 shows strain-hardening exponent for 10-20% strain for the various aluminum alloy samples.

[0093] The fine grain size and high degree of random textures resulted in good bending and roping character, and improved formability character, as compared to processing without use of an interannealing recrystallization process. Further, the clean microstructure having a low fraction of undissolved precipitates and microvoids contributed to the good bending character.

ILLUSTRATIVE ASPECTS

[0094] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4 ”).

[0095] Aspect 1 is an aluminum alloy, comprising Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content. [0096] Aspect 2 is the aluminum alloy of any previous or subsequent aspect, comprising up to 100% recycled aluminum alloy content or comprising more than 20% recycled aluminum alloy content.

[0097] Aspect 3 is the aluminum alloy of any previous or subsequent aspect, comprising a 6xxx series aluminum alloy.

[0098] Aspect 4 is the aluminum alloy of any previous or subsequent aspect, comprising about 1.2 wt.% to 1.5 wt.% Si, about 0.10 wt.% to 0.35 wt.% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.25 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.005 wt.% to 0.10 wt.% Cr, about 0.03 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.20 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.01 wt.% to 0.10 wt.% V.

[0099] Aspect 5 is the aluminum alloy of any previous or subsequent aspect, comprising about 1.35 wt.% to 1.5 wt.% Si, about 0.20 wt.% to 0.35 wt.% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.20 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt.% to 0.10 wt.% Cr, about 0.05 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.15 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.02 wt.% to 0.10 wt.% V.

[0100] Aspect 6 is the aluminum alloy of any previous or subsequent aspect, comprising up to 0.05 wt.% each of any individual impurity and up to 0.25 wt.% of all impurities.

[0101] Aspect 7 is the aluminum alloy of any previous or subsequent aspect, comprising more alpha phase Fe-containing intermetallic particles than beta phase Fe-containing intermetallic particles.

[0102] Aspect 8 is a metal product comprising an aluminum alloy, wherein the aluminum alloy comprises Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

[0103] Aspect 9 is the metal product of any previous or subsequent aspect, wherein the aluminum alloy is the aluminum alloy of any of any previous or subsequent aspect.

[0104] Aspect 10 is the metal product of any previous or subsequent aspect, wherein the metal product is a rolled metal product.

[0105] Aspect 11 is the metal product of any previous or subsequent aspect, wherein the metal product is dual-recrystallized metal product. [0106] Aspect 12 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits isotropic strain characteristics.

[0107] Aspect 13 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater.

[0108] Aspect 14 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an fl 5% bending factor along a transverse direction of from about 0.3 to 1.0.

[0109] Aspect 15 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10° to 60°. [0110] Aspect 16 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 pm.

[0111] Aspect 17 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper.

[0112] Aspect 18 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper.

[0113] Aspect 19 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper.

[0114] Aspect 19A is the metal product of any previous or subsequent aspect prepared using the method of any subsequent aspect.

[0115] Aspect 19B is the metal product of any previous aspect prepared using the aluminum alloy of any previous aspect.

[0116] Aspect 20 is a method of producing a metal product, the method comprising casting an aluminum alloy to generate a cast product, wherein the aluminum alloy comprises Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content; homogenizing the cast product to generate a homogenized product; hot rolling the homogenized product to generate a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product.

[0117] Aspect 21 is the method of any previous or subsequent aspect, further comprising subsequent to the hot rolling, subjecting the rolled product to a recrystallization process to generate a recrystallized product, wherein the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product.

[0118] Aspect 22 is the method of any previous or subsequent aspect, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.

[0119] Aspect 23 is the method of any previous or subsequent aspect, further comprising subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

[0120] Aspect 24 is the method of any previous or subsequent aspect, wherein the recrystallization process comprises annealing the rolled product at peak metal temperature of from 325 °C to 425 °C for up to 1 minute to generate a recrystallized product; and quenching the recrystallized product.

[0121] Aspect 25 is the method of any previous or subsequent aspect, wherein an exit temperature of the hot rolling is no more than 400 °C.

[0122] Aspect 26 is the method of any previous or subsequent aspect, wherein the hot rolling achieves a thickness reduction between the homogenized product and the rolled product of 90% or more.

[0123] Aspect 27 is the method of any previous or subsequent aspect, further comprising subjecting the metal product to a solutionizing process to generate a solutionized metal product.

[0124] Aspect 28 is the method of any previous or subsequent aspect, further comprising subjecting the metal product to an aging or artificial aging process to generate an aged metal product.

[0125] Aspect 29 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content or more than 20% recycled aluminum alloy content.

[0126] Aspect 30 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises a 6xxx series aluminum alloy.

[0127] Aspect 31 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises about 1.2 wt.% to 1.5 wt.% Si, about 0.10 wt.% to 0.35 wt.% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.25 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.005 wt.% to 0.10 wt.% Cr, about 0.03 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.20 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.01 wt.% to 0.10 wt.% V.

[0128] Aspect 32 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises about 1.35 wt.% to 1.5 wt.% Si, about 0.20 wt.% to 0.35 wt.% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.20 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt.% to 0.10 wt.% Cr, about 0.05 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.15 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.02 wt.% to 0.10 wt.% V.

[0129] Aspect 33 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises up to 0.05 wt.% each of any individual impurity and up to 0.25 wt.% of all impurities.

[0130] Aspect 34 is the method of any previous or subsequent aspect, wherein the metal product exhibits isotropic strain characteristics.

[0131] Aspect 35 is the method of any previous or subsequent aspect, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater.

[0132] Aspect 36 is the method of any previous or subsequent aspect, wherein the metal product exhibits an fl 5% bending factor along a transverse direction of from about 0.3 to 1.0. [0133] Aspect 37 is the method of any previous or subsequent aspect, wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10° to 60°.

[0134] Aspect 38 is the method of any previous or subsequent aspect, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 pm.

[0135] Aspect 39 is the method of any previous or subsequent aspect, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper.

[0136] Aspect 40 is the method of any previous or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper.

[0137] Aspect 41 is the method of any previous or subsequent aspect, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper. [0138] Aspect 42 is the method of any previous aspect, wherein the aluminum alloy is the aluminum alloy of any previous aspect.

[0139] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

WHAT IS CLAIMED IS:

1. An aluminum alloy, comprising Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

2. The aluminum alloy of claim 1, comprising up to 100% recycled aluminum alloy content or comprising more than 20% recycled aluminum alloy content.

3. The aluminum alloy of claim 1, comprising a 6xxx series aluminum alloy.

4. The aluminum alloy of claim 1, comprising: about 1.2 wt.% to 1.5 wt.% Si, about 0.10 wt.% to 0.35 wt.% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.25 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.005 wt.% to 0.10 wt.% Cr, about 0.03 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.20 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.01 wt.% to 0.10 wt.% V.

5. The aluminum alloy of claim 1, comprising: about 1.35 wt.% to 1.5 wt.% Si, about 0.20 wt.% to 0.35 wt.% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.20 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt.% to 0.10 wt.% Cr, about 0.05 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.15 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.02 wt.% to 0.10 wt.% V.

6. The aluminum alloy of claim 1, comprising up to 0.05 wt.% each of any individual impurity and up to 0.25 wt.% of all impurities.

7. The aluminum alloy of claim 1, comprising more alpha phase Fe- containing intermetallic particles than beta phase Fe-containing intermetallic particles.

8. A metal product comprising an aluminum alloy, wherein the aluminum alloy comprises Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

9. The metal product of claim 8, wherein the aluminum alloy is the aluminum alloy of any of claims 1-7.

10. The metal product of claim 8, wherein the metal product is a rolled metal product.

11. The metal product of claim 8, wherein the metal product is dualrecrystallized metal product.

12. The metal product of claim 8, wherein the metal product exhibits isotropic strain characteristics.

13. The metal product of claim 8, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater.

14. The metal product of claim 8, wherein the metal product exhibits an fl 5% bending factor along a transverse direction of from about 0.3 to 1.0.

15. The metal product of claim 8, wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10° to 60°.

16. The metal product of claim 8, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 pm.

17. The metal product of claim 8, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper.

18. The metal product of claim 8, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper.

19. The metal product of claim 8, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper.

20. A method of producing a metal product, the method comprising: casting an aluminum alloy to generate a cast product, wherein the aluminum alloy comprises Al and about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content; homogenizing the cast product to generate a homogenized product; hot rolling the homogenized product to generate a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product.

21. The method of claim 20, further comprising: subsequent to the hot rolling, subjecting the rolled product to a recrystallization process to generate a recrystallized product, wherein the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product.

22. The method of claim 21, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.

23. The method of claim 21, further comprising: subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

24. The method of claim 21, wherein the recrystallization process comprises: annealing the rolled product at peak metal temperature of from 325 °C to 425

°C for up to 1 minute to generate a recrystallized product; and quenching the recrystallized product.

25. The method of claim 20, wherein an exit temperature of the hot rolling is no more than 400 °C.

26. The method of claim 20, wherein the hot rolling achieves a thickness reduction between the homogenized product and the rolled product of 90% or more.

27. The method of claim 20, further comprising: subjecting the metal product to a solutionizing process to generate a solutionized metal product.

28. The method of claim 20, further comprising: subjecting the metal product to an aging or artificial aging process to generate an aged metal product.

29. The method of claim 20, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content or more than 20% recycled aluminum alloy content.

30. The method of claim 20, wherein the aluminum alloy comprises a 6xxx series aluminum alloy.

31. The method of claim 20, wherein the aluminum alloy comprises: about 1.2 wt.% to 1.5 wt.% Si, about 0.10 wt.% to 0.35 wt.% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.25 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.005 wt.% to 0.10 wt.% Cr, about 0.03 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.20 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.01 wt.% to 0.10 wt.% V.

32. The method of claim 20, wherein the aluminum alloy comprises: about 1.35 wt.% to 1.5 wt.% Si, about 0.20 wt.% to 0.35 wt.% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.20 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt.% to 0.10 wt.% Cr, about 0.05 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.15 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.02 wt.% to 0.10 wt.% V.

33. The method of claim 20, wherein the aluminum alloy comprises up to 0.05 wt.% each of any individual impurity and up to 0.25 wt.% of all impurities.

34. The method of claim 20, wherein the metal product exhibits isotropic strain characteristics.

35. The method of claim 20, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater.

36. The method of claim 20, wherein the metal product exhibits an fl 5% bending factor along a transverse direction of from about 0.3 to 1.0.

37. The method of claim 20, wherein the metal product exhibits an inner- bending angle after pre-straining of 10% of about 10° to 60°.

38. The method of claim 20, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 pm.

39. The method of claim 20, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper.

40. The method of claim 20, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper.

41. The method of claim 20, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper.

42. The method of claim 20, wherein the aluminum alloy is the aluminum alloy of any of claims 1-7.