WO2024112635A1 - Recycle-friendly aluminum alloys for use as fin stock and methods of making the same - Google Patents

Recycle-friendly aluminum alloys for use as fin stock and methods of making the same Download PDF

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Publication number
WO2024112635A1
WO2024112635A1 PCT/US2023/080477 US2023080477W WO2024112635A1 WO 2024112635 A1 WO2024112635 A1 WO 2024112635A1 US 2023080477 W US2023080477 W US 2023080477W WO 2024112635 A1 WO2024112635 A1 WO 2024112635A1
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aluminum alloy
alloy
aluminum
mpa
alloys
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PCT/US2023/080477
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French (fr)
Inventor
Monica KAPOOR
Eider A. SIMIELLI
Theresa Elizabeth MACFARLANE
John Erik CARSLEY
Patrick MCGANNON
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Novelis Inc.
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Publication of WO2024112635A1 publication Critical patent/WO2024112635A1/en

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent

Definitions

  • This disclosure relates to the fields of material science, material chemistry, metallurgy, aluminum alloys, aluminum alloy products, aluminum fabrication, and related fields. More specifically, the disclosure relates to recycle-friendly aluminum alloys that can be used in a variety of applications, including, for example, as fin stock for heat exchangers, that can replace aluminum alloys including a high content of prime aluminum.
  • aluminum alloys for producing fin stock require high thermal conductivity for heat transfer suitable for hear exchanger applications while also having a corrosion potential that is sufficiently negative for the fin stock to act in a sacrificial manner during corrosion of the heat exchanger.
  • Prime aluminum has a high thermal conductivity thereby providing good heat transfer properties.
  • Aluminum alloys that include high amounts of prime aluminum have higher thermal conductivity values than aluminum alloys that have less prime aluminum.
  • aluminum alloys that include solute elements dissolved in solution typically have lower thermal conductivity than aluminum alloys that include less solute elements.
  • fin stock is often fabricated from AA7072 aluminum alloy due to the high amounts of prime aluminum that provide good thermal conductivity and corrosion potential properties.
  • recycled aluminum alloy materials may be unsuitable for use in preparing high performance aluminum alloys such as AA7072 aluminum alloy as the recycled aluminum alloy materials may contain high levels of certain solute elements that negatively affect thermal conductivity and corrosion potential properties.
  • AA7072 aluminum alloy has strict bounds on composition and processing thereby severely limiting the amounts and types of recycled aluminum alloy materials that can be used.
  • Recycled aluminum alloy materials may include certain alloying elements (e.g., Si, Fe, and/or Mn) in amounts that adversely affect the properties of AA7072 aluminum alloy, such as thermal conductivity and corrosion potential. For these reasons, it is not practical to use high amounts of recycled aluminum alloy materials for producing aluminum alloys such as AA7072 aluminum alloy; without negatively impacting desirable alloy properties,
  • the aluminum alloys described herein comprise 0.10 - 1.30 wt. % Si, 0.10 - 1.00 wt. % Fe, up to 0.30 wt. % Cu, 0.01 - 0.80 wt. % Mn, 0,20 - 0.80 wt. % Mg, 0.50 - 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy comprises 0.20- 1.20 wt.
  • the aluminum alloy comprises 0.30 % Si, 0.20 - 0.90 wt. % Fe, 0.01 - 0.30 wt. % Cu, 0.05 - 0.70 wt. % Mn, 0.20 - 0.80 wt. % Mg, 0,50 - 3.25 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt, % Ti, up to 0, 15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy comprises 0.30
  • the aluminum alloy comprises 0,50 - 1,00 wt. % Si, 0,40 - 0.90 wt. % Fe, 0,01 - 0.30 wt, % Cu, 0.20 - 0.80 wt, % Mn, 0,20
  • the aluminum al loy comprises 0.60 - 1.00 wt, % Si, 0.70 - 1.00 wt. % Fe, 0.01 ⁇ 0.30 wt. % Cu, 0.30 - 0.70 wt. % Mn, 0.30 - 0.80 wt. % Mg, 1.00 - 2.50 wt % Zn, up to 0.05 wt.
  • the aluminum alloy comprises a combined content of Si and Fe from 0.50 wt. % to 2.30 wt. %. In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90:1. In some embodiments, the aluminum alloy comprises a combined content of Si and Fe of at least 1.30 wt. %, and wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2:1, In some embodiments, the aluminum alloy comprises 10 % more alpha phase particles than AA3105 aluminum alloy. In some embodiments, the aluminum alloy is a 3xxx series aluminum alloy. In some embodiments, an ultimate tensile strength of the aluminum alloy is at least 110 MPa. In some embodiments, a yield strength of the aluminum alloy is at least 50 MPa.
  • the aluminum alloy comprises a conductivity from 40 % to 60 % based on the international annealed copper standard (IACS).
  • the aluminum ahoy comprises a corrosion potential of from -740 mV to -820 mV.
  • a fin stock comprises the aluminum alloy described herein.
  • an aluminum alloy product comprises a tube and a fin, wherein the fin comprises the aluminum alloy described herein.
  • a method of producing an aluminum alloy product includes: casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.10 - 1.30 wt. % Si, 0.10 - 1.00 wt. % Fe, up to 0.30 wt. % Cu, 0.01 - 0.80 wt. % Mu, 0.20 •••• 0.80 wt. % Mg, 0.50 ••• 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt.
  • the homogenization step comprises heating the cast aluminum alloy to a homogenization temperature from 400 °C to 600 °C at a heating rate of at least 10° C/h and soaki ng the cast aluminum alloy at the homogenization temperature for a period of time from 5 hours to 15 hours.
  • the annealing step comprises heating the cast aluminum alloy to an annealing temperature from 300 °C to 500 °C at a heating rate of at least 10 °C/h and soaking the cast aluminum alloy at the annealing temperature for a period of time from 1 hour to 8 hours.
  • the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2: 1 and wherein the aluminum alloy product has an ultimate tensile strength of at least 110 MPa, a yield s trength of at least 50 MPa, and a conductivity of from 40 % to 60 % based on the international annealed copper standard (IACS).
  • IACS international annealed copper standard
  • a fin stock prepared by the method described herein.
  • aluminum alloy products comprising the aluminum alloys described herein.
  • the products can include a fin stock.
  • aluminum alloy products comprising a tube and a fin, wherein the fin comprises the aluminum alloys described herein.
  • Aluminum alloy products e.g., heat exchanger fins obtained according to the methods are also provided herein.
  • FIG. 1 is a graph showing the influence of alloying elements on the thermal conductivity of an aluminum alloy.
  • FIG. 2 is a graph of thermodynamic calculations of the mass fraction of alpha phase particles in an aluminum alloy as a function of the amount of Si and Fe in the aluminum alloy at different temperatures according to some embodiments.
  • FIG. 3 is a graph of the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022) according to some embodiments.
  • FIGS. 4A-4C are graphs of the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022) demonstrating the effect of the Si and Fe concentration according to some embodiments.
  • FIGS. 5A and 5B are graphs of the electrical conductivity (% IACS) as measured by ASTM E1004 (2022) of an AA3105 aluminum alloy at various annealing temperatures for different periods of time.
  • FIG. 6 is a graph of the el ectrical conductivity of the sample aluminum alloys in Table 17 after heat treatment (annealing) at 375 °C for four hours according to some embodiments.
  • FIG, 7 is a graph of the measured electrical potential difference ( ⁇ Eoc (mv)) of example 3xxx series aluminum alloys as a function of the Zn content according to some embodiments.
  • Described herein are recycle-friendly aluminum alloys which exhibit high thermal conductivity and good corrosion potential.
  • the aluminum alloys described herein incorporate higher amounts of recycled aluminum alloy materials and less primary aluminum, as compared to AA7072 aluminum alloys used to produce fin stock, and still maintain good mechanical properties for fin stock.
  • the aluminum alloys described herein include a careful balance of alloying elements that surprisingly provide good thermal conductivity and corrosion potential properties despite including less prime aluminum and a higher content of solute elements than AA7072 aluminum alloys.
  • higher amounts of solute elements and less prime aluminum in an aluminum alloy composition would result in poor thermal conductivity properties.
  • manganese (Mn) and other alloying elements are known to decrease thermal conductivity and ultimately the thermal efficiency of aluminum alloys.
  • a modified 3x.xx series aluminum alloy can include a balance of silicon (Si) and iron (Fe) to reduce the negative effects of Mnto provide good thermal conductivity properties. Additionally, the addition of zinc (Zn) to the modified 3xxx series aluminum alloy can increase the corrosion potential of the aluminum alloy.
  • the combination of properties provides an aluminum alloy that can replace AA7072 aluminum alloys for fin stock and provides a cost-effective alternative to the use of AA7072 aluminum alloys for fin stock.
  • AA7072 aluminum alloy for fin stock has a strictly controlled composition to meet the minimum thermal conductivity and corrosion resistance requirements for fin stock.
  • high thermal conductivity and adequate corrosion potential is required for aluminum alloys used to produce fin stock, which has dictated that such fin stock be fabricated from an aluminum alloy including high amounts of prime aluminum, such as AA7072 aluminum alloy.
  • prime aluminum such as AA7072 aluminum alloy.
  • AA7072 aluminum alloy cannot be produced from high amounts of recycled aluminum alloy .
  • materials because AA7072 aluminum alloy includes Zn as the major alloying element and minor amounts of Cu, Mn, and Mg.
  • recycled aluminum alloy materials may include Si, Fe, and other impurities.
  • the aluminum alloys described herein can utilize higher amounts of recycled aluminum alloy materials and achieve a combination of properties for heat exchanger applications. Specifically, the aluminum alloys described herein can tolerate higher amounts of Si, Fe, and/or Cu compared to AA7072 aluminum alloy and still achieve good thermal conductivity and adequate corrosion potential properties. Additionally; the aluminum alloys described herein may include additional Zn to improve corrosion potential.
  • the composition of the aluminum alloy described herein reduces the compositional gap between fin stock and recycled aluminum alloy materials to lower the amount of primary aluminum. By reducing the compositional gap between aluminum alloys for tin stock and recycled aluminum alloy materials, more recycled aluminum alloy may be used to produce aluminum alloys for fin stock.
  • the aluminum alloys described herein also possess sufficiently high thermal conductivity suitable for heat exchanger applications, and have a corrosion potential that is sufficiently negative for the fins to act in a sacrificial manner during corrosion of the heat exchanger.
  • the aluminum alloys described herein include amounts of Zn such that the aluminum alloy can be especially useful as a sacrificial alloy (e.g., as fin stock material for use in combination with copper or aluminum alloy tubes in heat exchangers).
  • the aluminum alloys described herein can be formed as fin stock and atached mechanically to copper or aluminum alloy tubing. The fin stock can sacrificially corrode, thus protecting the copper or aluminum alloy tubing from corrosion.
  • the aluminum alloys described herein can be used as fin stock in industrial applications, including in heat exchangers, or in other applications.
  • the aluminum alloys described herein serve as a sacrificial component, ensuring the protection of other components of the heat exch anger (e.g., a tube to which the alloy is attached).
  • the aluminum alloys described herein can be produced from input aluminum that is at least in part recycle-friendly. Definitions and Descriptions:
  • a plate generally has a thickness of greater than 15 mm.
  • a plate may refer to an aluminum product having a thickness of greater than 15 mm, greater than 20 nun, greater than 25 mm, greater than 30 mm, greater than 35 mm, greater than 40 mm, greater than 45 mm, greater than 50 nun, or greater than 100 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from 4 mm to 15 mm.
  • a shate may have a thickness of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.
  • a sheet generally refers to an aluminum product haying a thickness of less than 4 mm.
  • a sheet may have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm.
  • An F condition or temper refers to an aluminum alloy as fabricated.
  • An 0 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 an 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.
  • the aluminum alloy can be strain hardened to various tempers, for example. H16, H18, or other H1X tempers.
  • the following aluminum alloys are described in terms of their elemental composition in weight percentage ( wt. %) based on the total weight of the alloy. In certain examples of each alloy, the remainder is aluminum, with a maximum wi. % of 0.15 % for the sum of the impurities.
  • Electrochemical potential refers to a material’s amenability to a redox reaction. Electrochemical potential can be employed to evaluate resistance to corrosion of aluminum alloys described herein. A negative value can describe a material that is easier to oxidize (e.g., lose electrons or increase in oxidation state) when compared to a material with a positive electrochemical potential. A positive value can describe a material that is easier to reduce (e.g., gain electrons or decrease in oxidation state) when compared to a material with a negative electrochemical potential. Electrochemical potential, as used herein, is a vector quantity expressing magnitude and direction.
  • cast aluminum alloy As used herein, terms such as “cast aluminum alloy,” “cast article,” 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.
  • room temperature can include a temperature of from 15° C to 30“ C, for example 15“ C, 16“ C, 17° C, 18° C, 19° C, 20° C, 21° C, 22° C, 23° C, 24° C, 25° C, 26° C , 27° C, 28° C, 29° C, or 30° C.
  • the aluminum alloy is a 3xxx series aluminum alloy.
  • the aluminum alloy can be a modified AA3105 aluminum alloy.
  • the aluminum alloys described herein exhibit high thermal conductivity and corrosion potential that is significantly improved in comparison to 3xxx series aluminum alloys, and therefore can be used for fin stock.
  • the properties of the alloys are achieved due to the elemental compositions of the alloys, and, in some cases, also the methods of processing the alloys to produce the described sheets, plates, and shates.
  • 3xxx series aluminum alloys generally have poor thermal conductivity and corrosion performance at least in part due to its composition.
  • AA3105 aluminum alloy includes high amounts of Mn (e.g., up 0.80 wt. %) and other solute elements which decreases the thermal conductivity of the AA3105 aluminum alloy.
  • Mn in solid solution has one of the highest negative impacts on thermal conductivity per unit weight.
  • FIG. 1 shows that most solute elements generally decrease the thermal conductivity of the aluminum alloy. Without being bound by theory, the inventors have found that pulling Mn out of solid solution has the most beneficial impact on improving thermal conductivity of a 3xxx series aluminum alloy.
  • the inventors have unexpectedly found that the thermal conductivity of a 3xxx series aluminum alloy can be improved by tailoring the composition of the aluminum alloy to precipitate Mn and other solute elements into constituent particles and dispersoids (e.g., Mn-containing dispersoids). By removing Mn and other solute elements from the aluminum alloy matrix, the thermal conductivity of the aluminum alloy can be increased. With the appropriate process and composition control of the main alloying additions, the resultant microstructure exhibits a high number density of dispersoids which substantially increases the thermal conductivity of the aluminum alloy.
  • Mn-containing dispersoids e.g., Mn-containing dispersoids
  • the higher amount of Si and Fe in the aluminum alloy increases the amount of alpha phase and beta phase particles, thereby consuming Mn (e.g., pulling the Mn out of solid solution).
  • the Si content e.g., from 0.30 wt. % to 1.30 wt.
  • Fe content e.g., from 0.10 wt. % to 1.00 wt, %) decreases the amount of Mn in solid solution by forming alpha phase particles (e.g., Al 12 (Fe,M n) 3 Si) and beta phase particles (e.g., Al 1 (Fe,Mn)).
  • alpha phase particles e.g., Al 12 (Fe,M n) 3 Si
  • beta phase particles e.g., Al 1 (Fe,Mn
  • the aluminum alloy can be produced from recycled aluminum alloy materials (e.g., AA3105 aluminum alloy scrap).
  • the aluminum alloys and methods described herein can be used in industrial applications including sacrificial parts, heat dissipation, packaging, and building materials.
  • the aluminum alloys described herein can be employed as industrial fin stock for heat exchangers.
  • the fin stock produced from the aluminum alloys described herein can be provided as a recycle-friendly alternative to AA7072 aluminum alloy that provides comparable thermal conductivity, corrosion potential, and will still preferentially conode, protecting other metal parts incorporated in a heat exchanger.
  • the aluminum alloys can have the following elemental composition as provided in Table 1.
  • the aluminum alloys can have the following elemental composition as provided in Table 2.
  • the aluminum alloys can have the following elemental composition as provided in Table 3.
  • the aluminum alloys can have the following elemental composition as provided in Table 4.
  • the aluminum alloys can have the following elemental composition as provided in Table 5.
  • the alloy includes silicon (Si) in an amount from 0.10 % to 1.30 % (e.g., from 0.20 % to 1.20 %, from 0,30 % to 1.10 %, from 0.60 % to 0.90 %, from 0,50 % to 1.00 %, from 0.60 % to 1 .00 %, or from 0.80 % to 1.30 %) based on the total weight of the alloy.
  • the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %. 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25
  • Si a high density of alpha phase particles (e.g., Al 12 (Fe,Mn)sSi) and/or beta phase particles (e.g., Al 6 (Fe,Mn)) in the al uminum alloy microstruc ture.
  • alpha phase particles e.g., Al 12 (Fe,Mn)sSi
  • beta phase particles e.g., Al 6 (Fe,Mn)
  • alpha phase parti cles and beta phase particles takes free Mn out of solid solution during solidification (e.g., during casting) to reduce the negative effects of Mn on thermal conductivity. Additionally, homogenization orannealing can help pull out more Mn by growth of alpha particles and/or formation of alpha dispersoids which can further pull Mn out of solution.
  • the alloy also iron (Fe) in an amount from 0.10 % to 1.00 % (e.g., from 0,20 % to 0,90 %, from 0.30 % to 0.90 %, from 0.50 % to 0.90 %, from 0,40 % to 0.90 %, or .from 0.70 % to 1.00 %) based on the total weight of the alloy .
  • Fe iron
  • the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %,
  • Fe and Si promotes formation of Mn-containing dispersoids to improve thermal conductivity of the aluminum alloy.
  • Fe and Si can combine with Mn to produce a high density of alpha phase particles and/or beta phase particles to take free Mn out of solid solution during solidification (e.g., during casting) and after homogenization or annealing treatment to reduce the negative effects of Mn on thermal conductivity.
  • the alloy includes copper (Cu) in an amount from 0 % to 0.30 % (e.g., from 0.01 % to 0.30 %, from 0.01 % to 0.25 %, from 0.01 % to 0.20 %, or from 0.10 % to 0.30 %) based on the total weight of the alloy.
  • the alloy can include 0 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0,07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18%, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, or 0.30 % Cu. All percentages are expressed in wt. %. In some instances, a Cu content above 0.30 wt. % may lead to corrosion problems as it leads to positive corrosion potentials which is not desirable for fin stock materials.
  • the alloy includes manganese (Mn) in an amount from 0.01 % to 0.80% (e.g., from 0.05 % to 0.70 %, from 0.10 % to 0.70 %, from 0.20 % to 0.80 %, from 0.30 % to 0.70 %, or from 0.30 % to 0.50 %) based on the total weight of the alloy.
  • Mn manganese
  • the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19
  • Mn has largest negative impact on thermal conductivity. Mn largely remains in solid solution while a small amount is precipitated during solidification as constituents and as dispersoids during ingot pre-heating and annealing steps. The addition of Si and Fe in the amounts described herein promotes formation of Maintaining dispersoids to limit the negative impact of Mn on thermal conductivity.
  • the alloy included magnesium (Mg) in an amount from 0.20
  • the alloy can include 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %,
  • the alloy includes zinc (Zn) in an amount from 0.50 % to 3.50% (e.g., from 0.50 % to 3.25 %, from 0.60 % to 3.00 %, from 0.60 % to 2.75 %, from 0.50 % to 2.50 %, from 1.00 % to 2.50 %, or from 0.70 % to 2.50%) based on the total weight of the alloy.
  • Zn zinc
  • the alloy can include 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %,
  • the Zn content can improve the corrosion potential of the aluminum alloys described herein. Zn affects the anodic potential of aluminum alloys. Zn addition will cause an ahmunnm alloy to become more electronegative (sacrificial). In some embodiments, the Zn content of the aluminum alloys described herein is higher compared to AA3105 aluminum alloy such that the aluminum alloy will be able to act sacrificially when attached to copper or other aluminum alloy tubes, thus providing cathodic protection to the tubes. It is preferable in heat, exchanger units that the fin material is sacrificial to the tube material and that will depend on the composition of the tube material itself.
  • the difference in corrosion potential between the tubes and fin stock can be tailored for an adequate level of protection.
  • Zn when Zn is incorporated at a level as described herein, such as from 0.50 % to 3.50 %, the alloys exhibit a more adequate corrosion potential as compared to AA3105 aluminum alloy.
  • Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin.
  • the alloys for use as fins can corrode more rapidly than for fins containing the described amount of Zn, resulting in perforations in the fin. As a result, the mechanical integrity and thermal performance of the heat exchanger can be compromised, thus affecting the service life of the heat exchanger.
  • the alloy includes chromium (Cr) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy.
  • Cr chromium
  • the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0..16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Cr. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
  • the alloy includes titanium (Ti) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.1.0 %, or up to 0.05 ) based on the total weight of the alloy.
  • the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Ti.
  • the alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below; 0.03 % or below, 0.02 % or below, or 0.01 % or below each.
  • impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, So, Ca, Hf, Sr, or combinations thereof.
  • Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0,01 % or below.
  • the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt. %.
  • the remaining percen tage of the all oy is aluminum .
  • the aluminum alloy comprises a combined content of Si and Fe of at least 0.50 % (e.g,, at least 0.60 %, at least 0.70 %, at least 0.80 %, at least 0.90 %, at least 1.00 %, at least 1.10 %, at least 1.20%, at least 1 ,25 %, at least 1.30 %, at least 1.40 %, or at least 1.50 %).
  • the aluminum alloy comprises a combined content of Si and Fe from 0.50 % to 2.30 % (e.g., from 0.50 % to 1.80 %, from 0.60 % to 2.20 %, from 0.70 % to 2.10 %, from 0.80 % to 2.00 %, from 0.90 % to 1.80 %, from 1.00 % to 2.10 %, from 1.10 % to 2.20 %, from .1.20 % to 2.00 %, or from 1.70 % to 2.30 %). All percentages are expressed in wt. %.
  • the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90:1 (e.g., at least 1.00:1, at least 1.20:1, at least 1.40:1, at least 1.60:1, at least 1.80:1, at least 2.0:1, at least 2.20:1, at least 2.40:1 , or at least 2.5:1).
  • the aluminum alloy comprises a ratio of (Si + Fe):Mn from 0.90: 1 to 3.00: 1 (e.g., from 1.00: 1 to 3.00:1, from 1.20:1 to 2.90:1, from 1.10:1 to 2.80:1, from 1.20:1 to 2.75:1, from 1.25:1 to 2.60.1, from 1.40:1 to 2.50:1, or from 1.50:1 to 2.50:1).
  • the aluminum alloys can have the following elemental composition as provided in Table 6.
  • the aluminum alloys can have the following elemental composition as provided in Table 7.
  • the aluminum alloys can have the following elemental composition as provided in Table 8.
  • the aluminum alloys can have the following elemental composition as provided in Table 9.
  • the aluminum alloys can have the following elemental composition as provided in Table 10.
  • the aluminum alloys can have the following elemental composition as provided in Table 11.
  • the alloy includes Si in an amount from 0.40 % to 1.30 % (e.g,, from 0.50 % to 1.20 %, from 0.60 % to .1.10 %, from 0.70 % to 1,10 %, or from 0.50 % to 0.70 %) based on the total weight of the alloy.
  • the alloy can include 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0,44 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %,
  • the alloy includes Fe in an amount from 0.50 % to 2.50 % (e.g., from 0.50 % to 2.25 %, from 0.50 % to 2.00 %, from 0.60 % to 1.80 %, from 0.70 % to 1,50 %. from 0.90 % to 1.40 %, or from 0.70 % to 1.20 %) based on the total weight of the alloy.
  • the alloy can include 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %,
  • the alloy includes Cu in an amount from 0.10 % to 0.40 % (e.g., from 0.10 % to 0.30 %, from 0.15 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight, of the alloy.
  • the alloy can include 0.10 %.
  • the alloy includes Mn in an amount up to 1.00 % (e.g., up to 1.00 %, up io 0.90 %, up to 0.80 %, from 0.50 % to 1.00 %, from 0.50 % to 0.90 %, from 0.60 % to 0.90 %, from 0.60 % to 0.80 %, or from 0.50 % to 1.00 %) based on the total weight of the alloy.
  • up to 1.00 % e.g., up to 1.00 %, up io 0.90 %, up to 0.80 %, from 0.50 % to 1.00 %, from 0.50 % to 0.90 %, from 0.60 % to 0.90 %, from 0.60 % to 0.80 %, or from 0.50 % to 1.00 % based on the total weight of the alloy.
  • the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15
  • the aluminum alloy composition includes 0 % Mn. All percentages are expressed in wt. %.
  • the alloy includes Mg in an amount from 0.40 % to 0.80 % (e.g.. from 0.50 % to 0.80 %, from 0.60 % to 0.80 %, or from 0.40 % to 0.60 %) based on the total weight of the alloy.
  • the alloy can include 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %,
  • the alloy includes Zn in an amount up to 3.50 % (e.g., up to 3.25 %, up to 3.00 %, up to 2,75 %, or up to 2.50 %) based on the total weight of the alloy.
  • the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0,05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %,
  • the aluminum alloy composition includes 0 % Zu. All percentages are expressed in wt. %.
  • the Zn content can optionally be provided to improve the corrosion potential of the aluminum alloys described herein.
  • Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin.
  • the aluminum alloy includes at least 1.50 wt. % Zn to provide good corrosion potential.
  • the alloy includes Cr in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy.
  • the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0,04 % 5 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 %
  • Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt, %.
  • the alloy includes Ti in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy.
  • the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0,14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Ti.
  • the alloy can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or belo w each.
  • impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, H f, Sr, or combinations thereof.
  • Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0,05 % or below, 0.04 % or below, 0,03 % or below, 0.02 % or below, or 0.01 % or below.
  • the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt, %. In certain aspects, the remaining percentage of the alloy is aluminum.
  • the aluminum alloy composition comprises 0.50 - 0,70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt, % Cu, 0.50 — 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, up to 3.5 wt, % Zn, up to 0.05 wt, % Cr, up to 0.5 wt, % Ti, up to 0,15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt, % Fe, 0.10 - 0.20 wt, % Cu, 0.50 — 1.00 wt. % Mn, 0.40 - 0.60 wt, % Mg, 0.50 - 3.50 wt. % Zn, up to 0.05 wt, % Cr, up to 0.5 wt, % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy composition comprises 0.50 - 0.70 wt % Si, 0.70 - 1,20 wt. % Fe, 0.10 - 0,20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, 0,50 — 2.00 wt, % Zn, up to 0.05 wt. % Cr, up to 0.5 wt. % Ti, up to 0,15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy composi tion comprises 0.40 - 1.30 wt. % Si, 0.50 - 2.00 wt.
  • the aluminum alloy composition comprises 0.50 - 1.20 wt. % Si, 0.60 - 1.80 wt. % Fe, 0.10 - 0.30 wt. % Cu, 0.50 - 0.90 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.25 wt. % Zn, up to 0.15 wt. % Cr, up to 0.15 wt. % Ti, up to 0, 15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy composition comprises 0.60 - 1.10 wt. % Si, 0.70 - 1.50 wt. % Fe, 0.10 - 0.30 wt. % Cu, 0.60 - 0.90 wt. % Mn, 0.50 - 0.80 wt. % Mg, up to 3.00 wt. % Zn, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy composition comprises 0.70 - 1.10 wt. % Si, 0.90 - 1.40 wt. % Fe, 0.15 ⁇ 0.25 wt. % Cu, 0.60 - 0.80 wt. % Mn, 0.50 - 0.70 wt. % Mg, up to 2.75 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, up to 2,50 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti. up to 0.15 wt. % of impurities, and the remainder Al.
  • the aluminum alloy may include 0 wt. %
  • Zu based on the total weight of the aluminum alloy composition. For example, in embodiments where the aluminum alloy has sufficient corrosion potential or the aluminum alloy does not require a specific corrosion potential, little or no Zn is added to the aluminum alloy.
  • the aluminum alloy comprises a combined content of Si and Fe of at least 1.00 % (e.g., at least 1.10 %, at least 1.20%, at least 1.25 %, at least 1.30 % , at least 1.40 %, or at least 1.50 %).
  • the aluminum alloy comprises a combined content of Si and Fe from 1.00 % to 4.20 % (e.g., from 1.25 % to 4.00 %, from 1.30 % to 3.75 %, from 1.40 % to 3.50 %, from 1.50 % to 3.50 %, from 2.00 % to 4.00 %, from 2.50 % to 3.50 %, or from 3.00 % to 4.00 %).
  • the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least. 1.50:1 (e.g., at least 1.60:1, at least 1.70:1, at least 1.80:1, at least 1.90:1, at least 2.0:1, at least 2.10:1, at least 2.20:1, at least 2.30:1, at least 2.40:1, or at least 2.50: 1).
  • the aluminum alloy comprises a ratio of (Si + Fe):Mn from 1.50:1 to 4.50:1 (e.g., from 1.75.T to 4.00:1, from 1.80:1 to 3.75:1, from 1.90:1 to 3.50:1, from 2.00:1 to 3.00:1, or from 1.50:1 to 2.50:1).
  • the aluminum alloys can have the following elemental composition as provided in Table 12.
  • the aluminum alloys can have the following elemental composition as provided in Table 13.
  • the aluminum alloys can have the following elemental composition as provided in Table 14.
  • the aluminum alloys can have the following elemental composition as provided in Table 15.
  • the aluminum alloys can have the following elemental composition as provided in Table 16.
  • the alloy includes Si in an amount from 0.10 % to 1.30 %
  • the alloy can Include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %,
  • the alloy includes Fe in an amount from 0.10 % to 2.50 % (e.g., from 0.50 % to 2.25 %, from 0.60 % to 2.00 %, from 0.75 % to 2.00 %, from 0.80 % to 2.00 %, from 0.90 % to 2.00%, or from 1 .00 % to 2.00 %) based on the total weight of the alloy.
  • the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0,15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %. 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %,
  • the alloy includes Cu in an amount from 0 % to 0.30 % (e.g., from 0.01 % to 030 %, from 0.01 % to 0.25 %, from 0.01 % to 0.20 %, or from 0.10 % to 0.30 %) based on the total weight of the alloy.
  • the alloy can include 0 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0. 10 %, 0. 11 %, 0.
  • the alloy included Mn in an amount from 0.01 % to 0.80% (e.g., from 0.05 % to 0.70 %, from 0.10 % to 0.70 %, from 0.20 % to 0.80 %, from 0.30 % to 0.70 %, or from 0.30 % to 0.50 %) based on the total weight of the alloy,.
  • the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %,
  • the alloy includes Mg in an amount from 0.20 % to 0,80% (e.g., from 0.20 % to 0.80 %, from 0.25 % to 0.80 %, or from 0.30 % to 0.80 %) based on the total weight of the alloy.
  • the alloy can include 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %,
  • the alloy includes Zn in an amount from 0.50 % to 3.50% (e.g., from 0.50 % to 3.25 %, from 0.60 % to 3.00 %, from 0.60 % to 2.75 %, from 0.50 % to 2.50 %, from 1.00 % to 2.50 %, or from 0.70 % to 2.50%) based on the total weight of the alloy.
  • the alloy can include 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %. 0.55 %,
  • the alloy includes chromium (Cr) in an amount up to 0.20 % (e.g., up to 0.15 up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy.
  • the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08
  • the alloy includes titanium (Ti) in an amount up to 0.20 % (e.g., up to 0.15 up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy.
  • the alloy can include 0.001 %.
  • the alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below each.
  • impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, Sr, or combinations thereof.
  • Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr maybe present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below.
  • the sum of all impurities does not exceed 0...15 % (e.g., 0.1 %).
  • AH percentages are expressed in wt. %..
  • the remaining percentage of the alloy is aluminum.
  • the aluminum alloys described herein can tolerate higher amounts of recycled aluminum alloy materials and still exhibit desirable mechanical properties.
  • the impact of the impurities and/or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing a tailored aluminum alloy composition to compensate for the impurities. This enables a higher amount of less expensi ve, higher impurity recycled aluminum alloy materials (e.g., used 3xxx series aluminum alloy) for producing aluminum alloys that can still exhibit desirable properties.
  • the aluminum alloy compositions described herein can include higher amounts of recycled aluminum alloy ma terials compared to AA7072 aluminum alloy with little or no additional primary aluminum.
  • the aluminum alloy composition described herein provides a composition that is well-suited for utilizing used AA3105 aluminum alloy scrap as recycle material.
  • the aluminum alloy composition described herein can utilize UBC scrap.
  • UBC scrap is a mixture of various aluminum alloys (e.g. from different aluminum alloys used for can bodies and can ends).
  • UBC scrap generally includes a mixture of metal from various aluminum alloys, such as metal from can bodies (e.g., AA3104, AA3004, or other 3xxx series aluminum alloys) and can ends (e.g., AA5182 or other 5xxx series aluminum alloys).
  • UBC scrap can be shredded and de-coated or de- lacquered prior to being melted for use as liquid metal stock in casting a new metal product.
  • the aluminum alloy composition described herein can utilize recycled aluminum alloy materials (e.g., used AA3105 aluminum alloy scrap) to produce the aluminum alloy due to the aluminum alloy composition. This allows the use of more recycled aluminum alloy materials for producing fin end stock and reduces the amount of primary aluminum.
  • the aluminum alloys described herein include a high amount of recycled aluminum alloy materials scrap at or greater than 25 %, e.g., at or greater than 30 %, at or greater than 35 %, at or greater than 40 %, at or greater than 45 %, at or greater than 50 %, at or greater than 55 %, at or greater than 60 %, at or greater than 65 %, at or greater than 70 %, or at or greater than 75 %, In terms of ranges, the aluminum alloys described herein can include from 25 % to 90 % recycled aluminum alloy materials (e.g., from 25 % to 85 %, from 30 % to 80 %, from 35 % to 75 %, from 40 % to 70 %, from 50 % to 70 %, or from 35 % to 50 %).
  • 25 % to 90 % recycled aluminum alloy materials e.g., from 25 % to 85 %, from 30 % to 80 %, from 35 % to 75 %, from 40 % to 70
  • the aluminum alloys described herein are particularly well-suited to utilize used AA3105 aluminum alloy scrap.
  • the aluminum alloys described herein include less than 30 % primary ahtminum, e.g., less than 30 %, less than 29 %, less than 28 %, less than 27 %, less than 26 %, less than 25 %, less than 24 %, less than 23 %, less than 22 %, less than 21 %, or less than 20 %. All are expressed in wt. %.
  • the processes of producing aluminum al loys described herein lead to an aluminum material that can be described as “strain-hardened,” “cold-worked,” and/or having or being in “H1X” temper (e.g., H16 temper).
  • H1X e.g., H16 temper
  • the mechanical properties of the aluminum alloy can be controlled by various processing conditions depending on the desired use.
  • the alloy can be produced (or provided) in an H temper (e.g., HX1, HX2, HX3, HX4, HX5, HX6. HX7, HX8, or HX9 tempers).
  • the alloy can be produced (or provided) in the Hix or H2x temper. It is to be understood that a particular range of properties is associated with the temper designation.
  • the aluminum alloys described herein have high strength, corrosion potential, and thermal conductivity in the H tempers (e.g., H1x or H2x temper). In some embodiments, the aluminum alloys described herein have adequate corrosion potential in the H tempers (e.g., H16 temper). As a. result of controlling the composition and microstructure as described herein, the aluminum alloys described herein exhibit the following balance of properties.
  • the aluminum alloys can have a yield strength (YS) of at least 50 MPa.
  • the yield strength is at least 50 MPa, at least 60 MPa, at least 70 MPa, at least 80 MPa, at least 90 MPa, at least 100 MPa, at least 110 MPa, at least 120 M Pa, at least 130 M Pa, at least 140 MPa, at least 150 MPa, or at least 160 MPa, or anywhere in between.
  • the yield strength is from 50 MPa to 180 MPa.
  • the yield strength can be from 55 M Pa to 175 MPa, from 60 MPa to 170 M Pa, from 65 MPa to 165 MPa, from 70 MPa to 160 MPa. or from 75 MPa to 170 MPa.
  • the yield strength will vary based on the tempers of the alloys.
  • the alloys described herein provided in an H temper can have a yield strength of from at least 100 MPa to 170 MPa.
  • the yield strength of the alloys in H temper is at least 110 MPa, at least 120 MPa, at least 125 MPa, at least 130 MPa, at least 135 MPa, at least 140 MPa, at least 145 MPa, at least 150 MPa, at least 155 MPa. at least 160 MPa, at least 165 M Pa, at least 170 MPa, or anywhere in between.
  • the aluminum alloys described herein can have an ultimate tensile strength (UTS) of at least 110 MPa.
  • the yield strength is at least 110 MPa, at least 120 MPa, at least 130 MPa, at least 140 MPa, at least 150 MPa, at least 160 M Pa, at least 170 MPa, at least 180 MPa, at least 190 MPa, at least 200 MPa, or anywhere in between.
  • the yield strength is from 110 MPa to 240 MPa.
  • the yield strength can be from 115 M Pa to 235 MPa, from 125 MPa to 230 MPa, from 130 MPa to 225 MPa, from 140 MPa to 220 MPa, or from 150 MPa to 240 MPa.
  • the aluminum alloys described herein provided in an H temper can have an UTS of from at least 140 MPa to 200 .MPa.
  • the UTS of the alloys in H temper is at least 140 MPa, at least 145 MPa, at least 150 MPa, at least 155 MPa, at least 160 MPa, at least 165 MPa, at least 170 MPa, at least 175 MPa, at least 180 MPa, at least 190 MPa, or anywhere in between.
  • the aluminum alloys described herein have sufficient formability to meet an elongation of 2 % or greater.
  • the alloys described herein can have an elongation of 2 % or greater, 2.25 % or greater, 2.50 % or greater, 2.75 % or greater, 3 % or greater, 3.25 % or greater, 3.50 % or greater, 3.75 % or greater, 4 % or greater, 4.25 % or greater, 4.50 % or greater, 4,75 % or greater, 5.0 % or greater, 5.25 % or greater, 5.50 % or greater, 5.75 % or greater, 6.0 % or greater, or anywhere in between.
  • the aluminum alloys described herein can have an average conductivity val ue of above 40 % based on the international annealed copper standard (IACS) (e.g., from 40 % IACS to 60 % IACS).
  • IACS international annealed copper standard
  • the alloy can have an average conductivity value of 40 %, 41 %, 42 %, 43 %, 44 %, 45 %, 46 %, 47 %, 48 %, 49 %, 50 %, 51 %, 52 %, 53 %, 54 %, 55 %, 56 %, 57 %, 58 %, 59 %, 60 %, or anywhere in between. All values in % (ACS.
  • the aluminum alloys described herein can have a corrosion resistance that provides a negative corrosion potential or electrochemical potential (Ecorr) of -from -740mV to -820mV when tested according to the ASTM G69 standard. In certain cases, an open corrosion potential value vs.
  • Standard Calomel Electrode can be from - 740mV to -820mV (e.g., from -745 mV to -785 mV or from -755 mV to -790 mV), In certain cases, an open corrosion potential value vs, SCE can be -740mV, -750mV, -760mV, -770mV, -780mV, -790mV, -800mV, -810mV. or -820mV.
  • the properties of the aluminum alloy described herein is at least partially determined by the method of producing the aluminum alloy. Without, intending to limit the disclosure, aluminum alloy properties are partially determined by the formation of microstructures during the alloy’s preparation. In certain aspects, 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 method of producing the aluminum alloy described herein can improve thermal conductivity of the aluminum alloy.
  • the method may include a homogenization or annealing practice that can promote growth and coarsening of Mn-containing dispersoids (e.g., alpha phase particles).
  • Mn-containing dispersoids e.g., alpha phase particles
  • the homogenization or annealing practice can beneficially transform beta phase particles into alpha phase particles, which have a higher content of M.n than beta phase particles. In this way, the homogenization or annealing practice can be optimized to maximize the thermal conductivity of the aluminum alloy by taking M n out of solid solution.
  • the casting process can include a continuous (CC) casting process to produce a cast aluminum alloy.
  • the CC process may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters.
  • the casting process is performed by a CC process to form a cast aluminum alloy in the form of a billet, a slab, a shate, a strip, and the like.
  • the casting process can include a direct chill casting (DC) process.
  • DC direct chill casting
  • the cast aluminum alloy can then be subjected to further processing steps.
  • the processing methods as described herein can include the steps of homogenization/annealing, hot rolling, cold rolling, and/or annealing.
  • a homogenization step or annealing step can be performed.
  • the annealing step is used for contmuous casting processes. For example, for a cast aluminum alloy produced from a continuous casting process may be annealed and is not homogenized.
  • the homogenization step can include heating a cast aluminum alloy to a peak metal temperature of at least 400° C (e.g., at least 410° C, at least 420° C, at least 430° C, at least 440° C, at least 450° C, at least 460° C, at least 470° C, at least 480° C, at least 490° C, at least 500° C, at least 510° C, at least 520° C, at least 530° C, at least 540° C, at least 450° C, at least 460° C, at least 470° C, at least 480° C, at least 490° C, or at least 500° C).
  • a peak metal temperature e.g., at least 410° C, at least 420° C, at least 430° C, at least 440° C, at least 450° C, at least 460° C, at least 470° C, at least 480° C, at least 490° C, or at least 500° C).
  • the cast aluminum alloy can be heated to a peak metal temperature of from 400° C to 600° C (e.g., from 425° C to 600° C, from 450° C to 600° C, from 500° C to 600° C, from 500° C to 580° C, or from 500° C to 575° C).
  • the heating rate to the peak metal temperature can be 10° C/hour or greater (e.g., 20° C/hour or greater, 30° C/hour or greater, 40° C/hour or greater, 50° C/hour or greater, 60° C/hour or greater. 70° C/hour or greater, 80° C/hour or greater, 90° C/hour or greater, or 100° C/hour or greater).
  • the heating rate to the peak metal temperature can be from 10°- C/hour to 250° C/hour (e.g., 20° C/hour to 250° C/hour, 40° C/hour to 225° C/hour, 60° C/hour to 220° C/hour, from 80° C/hour to 200° C/hour, from 100° C/hour to 200° C/hour, or from 100° C/hour to 250° C/hour).
  • the cast aluminum alloy is then allowed to soak (i.e., held at the indicated temperature) for a period of time at the peak metal temperature range.
  • the cast aluminum alloy is allowed to soak for up to 20 hours (e.g., from 1 hour to 18 hours or from 6 hours to 15 hours).
  • the cast aluminum alloy can be soaked at the peak metal temperature from 500° C to 600° C for 1 hour, 2 hours. 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, or 20 hours.
  • the cast aluminum alloy is heated to a peak metal temperature from 500° C to 600° C at a heating rate of least 10° C/hour and soaked at the peak metal temperature for 6 hours to 15 hours.
  • the homogenization described herein can be carried out in a two-stage process.
  • the two-stage process can include the above- described heating and soaking steps, which can be referred to as the first stage, and can further inente a second stage.
  • the temperature of the cast aluminumalloy is increased to a temperature higher than the temperature used for the first stage.
  • the temperature for the second stage can be increased, for example, to a temperature at least 5° C higher than the peak metal temperature during the first stage.
  • the peak metal temperature can be increased to a temperature of at least 455" C (e.g., at least 460° C, at least 465° C, or at least 470° C).
  • the heating rate to the second stage temperature can be 5° C/hour or less, 3° C/hour or less, or 2.5° C/hour or less.
  • the cast aluminum alloy is then allowed to soak for a period of time during the second stage.
  • the cast aluminum alloy is allowed to soak for up to 10 hours (e.g., from 30 minutes to 10 hours, inclusively).
  • the cast aluminum alloy can be soaked in the second stage for 30 minutes, for 1 hour, for 2 hours, for 3 hours, for 4 hours, for 5 hours, for 6 hours, for 7 hours, for 8 hours, for 9 hours, or for 10 hours.
  • the aluminum alloy cast product is allowed to cool to room temperature.
  • an annealing step can be performed.
  • the annealing step can include heating a cast aluminum alloy to an annealing temperature of at least 300° C (e.g., at least 310° C, at least 320° C, at least 330° C, at least 340° C, at least 350° C, at least 360° C, at least 370° C, at least 380° C, at least 390° C, at least 400° C, at least 410° C, at least 420° C, at least 430° C, at least.440° C, or at least 450° C).
  • an annealing temperature of at least 300° C (e.g., at least 310° C, at least 320° C, at least 330° C, at least 340° C, at least 350° C, at least 360° C, at least 370° C, at least 380° C, at least 390° C, at least 400° C, at least 410° C, at least 420° C, at least 430°
  • the cast aluminum alloy can be heated to an annealing temperature of from 300° C to 500° C (e.g., from 325° C to 500° C, from 350° C to 500° C, from 300° C to 450° C, from 350° C to 450° C, from 300° C to 400° C, or from 400° C to 500° C).
  • the heating rate to the annealing temperature can be 10° C/hour or greater (e.g., 20° C/hour or greater, 30° C/hour or greater, 40° C/hour or greater, 50° C/hour or greater, 60° C/hour or greater, or 70° C/hour or greater).
  • the heating rate to the annealing temperature can be from 10° C/hour to 250° C/hour (e.g., 20° C/hour to 250° C/hour, 40° C/hour to 225° C/hour, 60° C/hour to 220° C/hour, from 80° C/hour to 200° C/hour, from 100° C/hour to 200° C/hour, or from 100° C/hour to 250° C/hour).
  • the cast aluminum alloy is then allowed to soak (i.e., held at the indicated temperature) for a period of time at the annealing temperature range.
  • the cast aluminum alloy is allowed to soak for up to 10 hours (e.g., from 30 minutes to 9 hours or 3 hours to 6 hours).
  • the cast aluminum alloy can be soaked at the annealing temperature from 300° C to 500° C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours. 8 hours, 9 hours, 10 hours, or anywhere in between.
  • the cast aluminum alloy is heated to an annealing temperature from 300° C to 500° C at a heating rate of least 10° C/hour and soaked at the annealing temperature for 6 hours to 15 hours.
  • the homogenization step or annealing step described herein can promote growth and coarsening of Mn-containing dispersoids (e.g., alpha particles). Additionally, the homogenization practice or annealing practice can beneficially transform beta phase particles into alpha phase particles, which have a higher content of Mn than beta phase particles. In this way, the homogenization step or annealing step can be optimized to maximize the thermal conductivity of the aluminum alloy by taking Mn out of solid solution.
  • Mn-containing dispersoids e.g., alpha particles.
  • the homogenization practice or annealing practice can beneficially transform beta phase particles into alpha phase particles, which have a higher content of Mn than beta phase particles. In this way, the homogenization step or annealing step can be optimized to maximize the thermal conductivity of the aluminum alloy by taking Mn out of solid solution.
  • a hot rolling step can be performed to produce a hot rolled product.
  • the cast aluminum alloy can be hot rolled to produce a hot rolled product at a temperature from 450° C to 560° C (e.g., from 460° C to 550° C, from 470° C to 540° C, from 480° C to 530° C, or from 490° C to 520° C).
  • the hot rolling temperature is 450° C, 460° C. 470° C, 480° C, 490° C, 500° C, 510° C , 520° C, 530° C, 540° C, 550° C or 560° C.
  • hot rolling temperature is too cold (e.g., less than 450° C), die hot roll loads are too high and may be susceptible to cracking. If the hot rolling temperature is too hot (e.g., greater than 560° C), the aluminum alloy may be too soft and break up in the hot rolling mill.
  • the cast aluminum alloy can be hot rolled to a 2 mm to 15 mm thick gauge (e.g., from 2.5 mtn to 12 rum thick gauge).
  • the cast aluminum alloy can be hot rolled to an 2 mm thick gauge, 2.5 mm thick gauge, 3 mm thick gauge, 3.5 mm thick gauge, 4 mm thick gauge, 5 mm thick gauge, 6 mm thick gauge, 7 mm thick gauge, 8 mm thick gauge, 9 mm thick gauge, 10 mm thick gauge, 11 mm thick gauge, 12 mm thick gauge, 13 mm thick gauge, 14 mm thick gauge, or 15 mm thick gauge.
  • the cast aluminum alloy can be hot rolled to a gauge greater than 15 mm (i.e., a plate).
  • the cast aluminum alloy can be hot rolled to a gauge less than 4 mm (i.e., a sheet).
  • a cold rolling step can be performed.
  • the cold rolling step can include one or more cold rolling passes.
  • the hot rolled product from the hot rolling step e.g., the plate, shate, or sheet
  • this thin-gauge shate or sheet is cold rolled to have a thickness (i.e. , a first thickness) ranging from 1.0 mm to 10.0 mm, or .from 2.0 mm to 8.0 mm, or from 3.0 mm to 6.0 mm, or from 4.0 mm to 5.0 mm.
  • this thin-gauge shate or sheet is cold rolled to have a thickness of 12.0 mm, 11.9 mm, 11.8 mm, 11.7 mm, 11.6 mm, 11.5 mm, 11.4 mm, 11.3 mm, 11.2 mm, 11.1 mm, 11.0 mm, 10.9 mm, 10.8 mm, 10.7 mm, 10.6 mm, 10.5 mm, 10.4 mm, 10.3 mm, 10.2 mm, 10.1 mm, 10.0 mm, 9.9 mm, 9.8 mm, 9.7 mm, 9.6 mm, 9.5 mm, 9.4 mm, 9.3 mm, 9.2 mm, 9.1 mm, 9.0 mm, 8.9 mm, 8.8 mm, 8.7 mm, 8.6 mm, 8.5 mm, 8.4 mm, 8.3 mm, 8.2 mm, 8.1 mm, 8.0 mm, 7.9 mm, 7.8 mm, 7.7 mm, 7.6 mm, 7.5 mm
  • the one or more cold rolling passes reduce the thickness of the hot rolled product by at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, or at least 70%. In some embodiments, the one or more cold rolling passes reduces the hot rolled product to a thickness (i.e., a first thickness) of no more than 10 mm, no more than 9 mm, no more than 8 mm, no more than 7 mm, no more than 6 mm, or no more than 5 mm.
  • a thickness i.e., a first thickness
  • the cold rolling step is a two-stage cold rolling step.
  • the two- stage cold rolling step can comprise a first cold rolling step, an optional intervening inter- annealing step, and a second cold rolling step.
  • the method can further comprise annealing the rolled product after the second cold rolling step.
  • an optional inter-annealing step can be performed during the two-stage cold rolling step.
  • the hot rolled product can be cold rolled to an intermediate gauge aluminum alloy product (first cold rolling step), annealed, and subsequently cold rolled to a final gauge aluminum alloy product (second cold rolling step).
  • the optional inter-annealing can be performed in a batch process (i.e., a batch inter-annealing step) or in a continuous process.
  • the inter-annealing step can be performed at a temperature of from 250° C to 450° C (e.g., 250° C, 260° C, 270° C, 280° C, 290° C, 300° C, 310° C, 320° C, 330° C, 340° C, 350° C, 360° C, 370° C, 380° C, 390° C, 400° C, 410° C, 420° C, 430° C, 440° C, or 450° C).
  • 250° C to 450° C e.g., 250° C, 260° C, 270° C, 280° C, 290° C, 300° C, 310° C, 320° C, 330° C, 340° C, 350° C, 360° C, 370° C, 380° C, 390° C, 400° C, 410° C, 420° C, 430° C, 440° C, or 450° C.
  • the heating rate in the inter-annealing step can be 100° C/hour or less, 75° C/hour or less, 50° C/hour or less, 40° C/hour or less, 30° C/hour or less, 25° C/hour or less, 20° C/hour or less, or 15° C/hour or less.
  • the heating rate can be from 10° C/hour to 100° C/hour (e.g., from 10° C/hour to 90° C/hour , from 1 0° C/hour to 70° C/hour , from 10° C/hour to 60° C/hour, from 20° C/hour to 90° C/hour, from 30° C/hour to 80° C/hour , from 40° C/hour to 70° C/hour , or from 50° C/hour to 60° C/hour),
  • 10° C/hour to 100° C/hour e.g., from 10° C/hour to 90° C/hour , from 1 0° C/hour to 70° C/hour , from 10° C/hour to 60° C/hour, from 20° C/hour to 90° C/hour, from 30° C/hour to 80° C/hour , from 40° C/hour to 70° C/hour , or from 50° C/hour to 60° C/hour
  • 10° C/hour to 100° C/hour e.g
  • the cold rolled product is allowed to soak for a period of time during the inter-annealing step. In some examples, the cold rolled product is allowed to soak for up to 5 hours (e.g., from 30 minutes to 4 hours, from 45 minutes to 3 hours, or from 1 hour to 2 hours, inclusively). For example, the cold rolled product can be soaked at a temperature of from 250° C to 450° C for 20 minutes. 30 minutes, 45 minutes, 1 hour, 1.5 hours, 2 hours, 3 hours, 4 hours, 5 hours, or anywhere in between. In some examples, the cold rolled product can be soaked at a temperature of 400° C for 4 hours.
  • the aluminum alloys described herein when produced according to the methods described herein include dispersoids that result in improved mechanical properties.
  • the aluminum alloys described herein includes higher amoun t of Si and Fe compared to AA3105 aluminum alloy to produce greater amounts of Mn-containing dispersoids.
  • Mn in solid solution has the greatest negative impact on thermal conductivity.
  • the aluminum alloy composition in combination with the method of producing the aluminum alloy promotes formations of alpha phase particles that decreases the amount of Mn in solid solution.
  • the amounts of Si and Fe in the aluminum alloys described herein results in higher amounts of alpha phase particles (e.g., Al 12 (Fe,Mn) 3 Si)) compared to AA3105 aluminum alloy.
  • the homogenization or annealing practice described herein promotes growth and coarsening ofMn-containing dispersoids (e.g., alpha phase particles) and converts beta phase particles into alpha phase particles, which have a higher content of Mn than beta phase particles.
  • the homogenization or annealing practice can be optimized to maximize the thermal conductivity of the aluminum alloy by removing Mn from solid solution.
  • the aluminum alloys described herein when produced according to the methods described herein includes greater than 5 % of alpha phase particles compared to AA3105 aluminum alloy (e.g., greater than 6 % greater than 7 %, greater than 8 %, greater than 9 %, greater than 10 %, greater than 11 %, greater than 12 %, greater than 13 %, greater than 14%, or greater than 15 %).
  • the aluminum alloys described herein when produced according to the methods described herein includes from 5 % to 30 % more alpha phase particles compared to AA3105 aluminum alloy (e.g.. from 6 % to 28 %, from 8 % to 26 %, from 10 % to 25 %, from 12 % to 25 %, from 15 % to 25 %, or from 10 % to 20 %),
  • the aluminum alloys described herein when produced according to the methods described herein includes less than 20 % of beta phase particles compared to AA3105 aluminum alloy (e.g., less than 18 %, less than 16 %, less than 15 %, less than 14 %, less than 12 %, or less than 10 %). In some embodiments, the aluminum alloys described herein when produced according to the methods described herein includes from 2 % to 30 % less beta phase particles compared to AA3105 aluminum alloy (e.g., from 2 % to 28 %, from 4 % to 26 %, from 5 % to 25 %, from 8 % to 22 %, from 8 % to 15 %, or from 10 % to 15 %).
  • the aluminum alloys and methods described herein can be used in industrial applications including sacrificial parts, heat dissipation, packaging, and building materials.
  • the aluminum alloys described herein can be used in various applications, for example, for manufacturing fins for heat exchangers.
  • the improved aluminum alloys described herein are useful for high performance, light weight automotive heat exchangers. More generally, the aluminum alloys described herein can be used in motor vehicle heat exchangers such as radiators, condensers and evaporators.
  • the compositions and the processes for producing the improved aluminum alloys described herein lead to a material possessing a combination of beneficial characteristics and properties that make it suitable for manufacturing heat exchanger fins.
  • the uses and applications of the improved aluminum alloys described herein are not limited to automotive heat exchangers and other uses are envisioned. It is to be understood that the characteristics and properties of the aluminum alloys described herein can also be beneficial for uses and applications other than the production of automotive heat exchanger fins.
  • the improved aluminum alloys described herein can be used for manufacture of various devices employing heat exchangers and produced by joined parts, such as devices employed in heating, ventilation, and air conditioning (HVAC).
  • HVAC heating, ventilation, and air conditioning
  • the aluminum alloys disclosed herein are suitable substitutes for metals conventionally used in indoor and outdoor HVAC units.
  • indoor refers to a placement contained within any structure produced by humans with controlled environmental conditions.
  • outdoor refers to a placement not fully contained within any structure produced by humans and exposed to geological and.
  • meteorological environmental conditions comprising air, solar radiation, wind, rain, sleet, snow, freezing rain, ice, hail, dust storms, humidity, aridity, smoke (e.g., tobacco smoke, house fire smoke, industrial incinerator smoke and wild fire smoke), smog, fossil feel exhaust, bio-fuel exhaust, salts (e.g., high salt content air in regions near a body of salt water), radioactivity, electromagnetic waves, corrosive gases, corrosive liquids, galvanic metals, galvanic alloys, corrosive solids, plasma, fire, electrostatic discharge (e.g., lightning), biological materials (e.g., animal waste, saliva, excreted oils, vegetation), wind-blown particulates, barometric pressure change, and diurnal temperature change.
  • the aluminum alloys described herein provide better corrosion performance and higher strength as compared to alloys currently employed.
  • the aluminum alloys described herein can be used in busbars, for example, as a conductive busbar.
  • busbars generally refer to a metal strip or bar used to carry current, tor example, for power distribution.
  • the aluminum alloys described herein can be used to produce transformers or portions of transformers. The high electrical conductivity of the aluminum alloy make these alloys particularly suitable for producing busbars and transformers.
  • Illustration 1 An aluminum alloy comprising 0,10 - 1.30 wt. % Si, 0.10 - 1.00 wt. % Fe, up to 0.30 wt. % Cu, 0.01 - 0.80 wt % Mn, 0.20 --- 0.80 wt. % Mg, 0.50 - 3.50 wt, % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0,15 wt. % of impurities, and the remainder AL
  • Illustration 2 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.20 - 1.20 wt. % Si, 0.20- 0,90 wt. % Fe, 0.0.1 - 0.30 wt. % Cu, 0.05 - 0,70 wt, % Mn, 0.20 - 0.80 wt. % Mg, 0.50 - 3.25 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
  • Illustration 3 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.30 - 1.10 wt.
  • Illustration 4 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.50 1.00 wt. % Si, 0.40 - 0.90 wt. % Fe, 0.01 - 0,30 wt.
  • Illustration 5 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.60 - 1.00 wt. % Si, 0.70 - 1.00 wt. % Fe, 0.01 - 0.30 wt. % Cu, 0.30 - 0.70 wt, % Mn, 0,30 - 0.80 wt. % Mg, 1.00 - 2.50 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
  • Illustration 6 The il lustration of any preceding or subsequent ill ustration, wherein the aluminum alloy comprises a combined content of Si and Fe from 0.50 wt. % to 2.30 wt. %.
  • Illustration 7 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90: 1.
  • Illustration 8 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a combined content of Si and Fe of at least 1.30 wt. %, and wherein the aluminum alloy comprises a ratio of (Si + Fe):Mnof at least 2:1.
  • Illustration 9 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 10 % more alpha phase particles than AA3105 aluminum alloy.
  • Illustration 10 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy is a 3xxx series aluminum alloy.
  • Illustration 11 The illustration of any preceding or subsequent illustration, wherein an ultimate tensile strength of the aluminum alloy is at least 110 MPa.
  • Illustration 12 The illustration of any preceding or subsequent illustration, wherein a yield strength of the aluminum alloy is at least 50 MPa.
  • Illustration 13 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a conductivity from 40 % to 60 % based on the international annealed copper standard (IACS).
  • IACS international annealed copper standard
  • Illustration 14 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a corrosion potential from -740 mV to -820 mV.
  • Illustration 15 A fin stock comprising the aluminum alloy of any preceding or subsequent illustration.
  • Illustration 16 An aluminum alloy product comprising a tube and a fin, wherein the fin comprises the aluminum alloy of any preceding or subsequent illustration.
  • Illustration 17 A method of producing an aluminum alloy product, the method comprising: casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.10 - 1.30 wt % Si, 0.10 - 1.00 wt. % Fe, up to 0,30 wt. % Cu, 0.01 - 0.80 wt. % Mn, 0.20 - 0.80 wt, % Mg, 0.50 - 3.50 wt, % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al; homogenizing or annealing the cast aluminum alloy; hot rolling the cast, aluminum alloy to produce a hot rolled product; and cold rolling the hot rolled product to produce to an aluminum alloy product,
  • Illustration 18 The illustra tion of any preceding or subsequent illustration, wherein the homogenization comprises heating the cast aluminum alloy to a homogenization temperature from 400 ° C to 600 °C at a heating rate of at least 10° C/h and soaking the cast aluminum alloy at the homogenization temperature for a period of time from 5 hours to 15 hours; and wherein the annealing step comprises heating the cast aluminum alloy to an annealing temperature from 300 ° C to 500 °C at a heating rate of at least 10° C/h and soaking the cast aluminum alloy at the annealing temperature for a period of time from 1 hour to 8 hours.
  • Illustration 19 The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2:1 and wherein the aluminum alloy product has an ultimate tensile strength of at least 1 10 MPa, a yield strength of at least 50 MPa, and a conducti vity from 40 % to 60 % based on the international annealed copper standard (IACS).
  • IACS international annealed copper standard
  • Illustration 20 A fin stock prepared by the method of claim of any preceding or subsequent illustration.
  • FIG. 2 shows a graph of thermodynamic calculations of the mass fraction of alpha phase particles in an aluminum alloy as a function of the amount of Si and Fe in the aluminum alloy at different temperatures.
  • the thermodynamic calculations were performed for aluminum alloys that include 1.25 wt. % Mn.
  • the thermodynamic calculations show that increasing Si and Fe does not linearly increase alpha phase particles.
  • aluminum alloys including higher Fe content reduces the amount of alpha phase particles.
  • Curve 1 represents an aluminum alloy including 0.70 wt. % Fe and 0.80 wt. % Si
  • Curve 2 represents an aluminum alloy including 2.0 wt. % Fe and 0.80 wt. % Si
  • Curve 3 represents an aluminum alloy including 0,70 wt.
  • the aluminum alloys represented by Curves 1 and 2 include the same amount of Si, but the aluminum alloy represented by Curve 2 has a substantially higher Fe content.
  • the aluminum alloy represented by Curve 2 had less alpha phase particle formation than the aluminum alloy represented by Curve 1 despite having higher amounts of Fe. Therefore, a balance of Si and Fe is needed to produce the optimal amount of alpha phase particles to pull Mg out of solid solution for good electrical conductivity. It was surprisingly found that the amounts of Fe and Si in an aluminum alloy composition can be optimized to maximize the formation of alpha phase particles for improved electrical conductivity properties.
  • Sample aluminum alloys were tested to determine the effect of the aluminum alloy on the electrical conductivity of aluminum alloys.
  • Sample Alloys 1-29 were prepared from various aluminum alloy compositions to demonstrate the effect of the aluminum alloy composition on the electrical conductivity, Comparative Example 1 was prepared from a AA3105 aluminum alloy in a H28 temper.
  • Comparative Example 2 was prepared from a AA3105 aluminum alloy in a H19 temper.
  • Comparative Example 3 was prepared front a continuous cast AA3105 aluminum alloy, and Comparative Example 4 was prepared from a AA7072 aluminum alloy.
  • Comparative Example 4 is the baseline for aluminum alloys with good thermal conductivity properties.
  • the aluminum alloys described herein are modified 3xxx series aluminum alloys that achieve electrical conductivity properties similar to AA7072 aluminum alloy; however, due to the composition, can include higher amounts of recycled materials, thus providing a cost-effective and recycle-friendly alternative to AA7072 aluminum alloy.
  • Sample Alloys 1-29 and Comparatives 1-4 were lab cast. The compositions of the alumin um alloys are provided below in Table 17.
  • FIG.3 shows the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022), Comparative Alloys 1-3 each exhibited an electrical conductivity less than 40 % IACS, whereas Sample Alloys 6, 10, 1 , 21, 19, 26, 27, 22, 29, 17, 20, 24, 11, 14, 28, 9, 15, 13, and each exhibited an electrical conductivity greater than 45 % IACS. For example, some sample aluminum alloys had greater than a 50 % increase in electrically conductivity compared to Comparative Examples 1-3.
  • the data demonstrates that modifying the composition of a 3xxx series aluminum alloy (e.g., AA3105 aluminum alloy) can substantially improve electrical conductivity properties.
  • FIG.4A-4C are graphs showing the effect of the Si and Fe on the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022).
  • FIG.4A shows the effec t of Si and Fe content on the electrical conductivity properties of an aluminum alloy including 0.55 wt, % Mn
  • FIG.4B shows the effect of Si and Fe content on the electrical conductivity properties of an aluminum alloy including 0.65 wt. % Mn
  • FIG, 4C shows the effect of Si and Fe content on the electrical conductivity properties of an aluminum alloy including 0.75 wt. % Mn.
  • the data demonstrates that increasing Si and Fe does not increase alpha phase particles ⁇ in some cases, higher Fe reduces the amount of alpha phase particles. Therefore, a balance of Si and Fe is needed to produce the optimal amount of alpha phase particles to pull Mg out of solid solution for good electrical conductivity.
  • Sample aluminum alloys were tested to determine the effect of heat treatment on the electrical conductivity of 3xxx series aluminum alloys.
  • An AA3105 aluminum alloy hot band was provided.
  • the AA3105 aluminum alloy hot band had an exit temperature from hot rolling of less than 300 °C.
  • the AA3105 aluminum alloy hot band was either subjected to: Process 1: cold rolling followed by annealing at temperatures from 300 °C to 475 °C for 2 to 24 hours; or Process 2: annealing at temperatures from 300 °C to 450° C for 2 to 24 hours.
  • FIGS.5A and SB are graphs of the electrical conductivity (% IACS) as measured by ASTM E1004 (2022) of an AA3105 ahtminum alloy hot band produced by Process 1 and 2 at various annealing temperatures for different periods of time.
  • the dashed line represents AA3105 aluminum alloy hot band that was subjected to Process I (cold rolling and annealing) and the solid line represents AA3105 aluminum alloy hot band that was subjected to Process 2 (annealing).
  • the electrical conductivity of the AA3105 aluminum alloy hot band without heat treatment (not plotted) after 24 hours was 37 % IACS.
  • FIGS.5 A and 5B show that annealing after hot rolling or cold rolling improved electrical conductivity compared to the AA3105 aluminum alloy hot band without heat treatment.
  • the AA3105 aluminum alloy hot band that was subjected to Process 1 or Process 2 each demonstrated an electrical conductivity greater than 39 % IACS when heated for 2 hours at an annealing temperature of 300 °C or greater.
  • the electrical conductivity for the AA3105 aluminum alloy hot band increased substantially after annealing.
  • cold rolling followed by annealing also improved electrical conductivity, Therefore. the data demonstrates that heat treating a AA3105 aluminum alloy hot band will increase the amount of alpha phase particles and improve electrical conductivity.
  • FIG. 6 shows a graph of the electrical conductivity of the sample aluminum alloys in Table 17 after heat treatment.
  • the sample aluminum alloys were annealed at a temperat ure of 375 °C for four hours.
  • Eac h of the sample al uminum alloys demonstrate some improvement in electrically conductivity after heat treatment.
  • heat treatment for Sample Alloys 8, 9, 16, 19, 20, and 28 showed synergistic improvements in electrical conductivity. It is contemplated that the aluminum alloy composition in tandem with the heat treatment can synergistically increase the amount of alpha phase particles and improve electrical conductivity.
  • FIG. 7 is a graph of the measured electrical potential difference (AEoc (mV)) of Alloys 30-33 according to ASTM G71 (2023) as a function of the Zn content.
  • the measured electrical potential difference for a 3xxx series aluminum alloy increases as a function of the Zn content in the alloy.
  • a 3xxx series aluminum alloy has an electrical potential difference of about 100 mV, which is comparable to benchmark AA7072 aluminum alloy.

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Abstract

Disclosed herein are recycle-friendly aluminum alloys, methods of making and processing such alloys, and products prepared from such alloys. More particularly, disclosed are recycle-friendly aluminum alloys exhibiting good thermal conductivity and corrosion potential properties despite being produced from less prime aluminum. The aluminum alloys can be used as fin stock in industrial applications, including in heat exchangers.

Description

RECYCLE-FRIENDLY ALUMINUM ALLOYS FOR USE AS FIN STOCK AND METHODS OF MAKING THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/384,869 filed November 23, 2022, U.S. Provisional Application No, 63/491 ,209 filed Match 20, 2023, U.S. Provisional Application No. 63/495,263 filed April 10, 2023, and U.S. Provisional Application No, 63/513,389 filed July 13, 2023, which are incorporated herein by reference in their entireties for all intents and purposes.
FIELD
[0002] This disclosure relates to the fields of material science, material chemistry, metallurgy, aluminum alloys, aluminum alloy products, aluminum fabrication, and related fields. More specifically, the disclosure relates to recycle-friendly aluminum alloys that can be used in a variety of applications, including, for example, as fin stock for heat exchangers, that can replace aluminum alloys including a high content of prime aluminum.
BACKGROUND
[0003] Generally, aluminum alloys for producing fin stock require high thermal conductivity for heat transfer suitable for hear exchanger applications while also having a corrosion potential that is sufficiently negative for the fin stock to act in a sacrificial manner during corrosion of the heat exchanger. Prime aluminum has a high thermal conductivity thereby providing good heat transfer properties. Aluminum alloys that include high amounts of prime aluminum have higher thermal conductivity values than aluminum alloys that have less prime aluminum. Additionally, aluminum alloys that include solute elements dissolved in solution (e.g., Si and/or Fe and/or Mn) typically have lower thermal conductivity than aluminum alloys that include less solute elements. As a result, fin stock is often fabricated from AA7072 aluminum alloy due to the high amounts of prime aluminum that provide good thermal conductivity and corrosion potential properties.
[0004] There has been an interest in using recycled aluminum alloy materials for producing aluminum alloys used in heat exchangers. However, recycled aluminum alloy materials may be unsuitable for use in preparing high performance aluminum alloys such as AA7072 aluminum alloy as the recycled aluminum alloy materials may contain high levels of certain solute elements that negatively affect thermal conductivity and corrosion potential properties. Additionally, AA7072 aluminum alloy has strict bounds on composition and processing thereby severely limiting the amounts and types of recycled aluminum alloy materials that can be used. Recycled aluminum alloy materials may include certain alloying elements (e.g., Si, Fe, and/or Mn) in amounts that adversely affect the properties of AA7072 aluminum alloy, such as thermal conductivity and corrosion potential. For these reasons, it is not practical to use high amounts of recycled aluminum alloy materials for producing aluminum alloys such as AA7072 aluminum alloy; without negatively impacting desirable alloy properties,
SUMMARY
[0005] Covered embodiments of the in ven tion are defined by the c laims, not this summary. This summary is a high-level overview of various aspects of the invention 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 , any or all drawings and each claim.
[0006] Provided herein are recycle-friendly aluminum alloys that exhibit high thermal conductivity and adequate corrosion potential properties despite being produced from less prime aluminum. The aluminum alloys described herein comprise 0.10 - 1.30 wt. % Si, 0.10 - 1.00 wt. % Fe, up to 0.30 wt. % Cu, 0.01 - 0.80 wt. % Mn, 0,20 - 0.80 wt. % Mg, 0.50 - 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises 0.20- 1.20 wt. % Si, 0.20 - 0.90 wt. % Fe, 0.01 - 0.30 wt. % Cu, 0.05 - 0.70 wt. % Mn, 0.20 - 0.80 wt. % Mg, 0,50 - 3.25 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt, % Ti, up to 0, 15 wt. % of impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises 0.30
— 1.10 wt, % Si, 0.30 - 0.90 wt. % Fe, 0.01 - 0.25 wt. % Cu, 0.10 -- 0.70 wt % Mn, 0.20 - 0.80 wt. % Mg, 0.60 - 3,00 wt. % Zn, up to 0, 15 wt. % Cr, up to 0.15 wt, % Ti, up to 0.15 wt. % of impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises 0,50 - 1,00 wt. % Si, 0,40 - 0.90 wt. % Fe, 0,01 - 0.30 wt, % Cu, 0.20 - 0.80 wt, % Mn, 0,20
- 0.80 wt. % Mg, 0.70 - 2.75 wt. % Zn, up to 0.10 wt. % Cr, up to 0.1.0 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. In some embodiments, the aluminum al loy comprises 0.60 - 1.00 wt, % Si, 0.70 - 1.00 wt. % Fe, 0.01 ~ 0.30 wt. % Cu, 0.30 - 0.70 wt. % Mn, 0.30 - 0.80 wt. % Mg, 1.00 - 2.50 wt % Zn, up to 0.05 wt. % Cr, up to 0.05 wt % Ti, up to 0.15 wt. % of impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises a combined content of Si and Fe from 0.50 wt. % to 2.30 wt. %. In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90:1. In some embodiments, the aluminum alloy comprises a combined content of Si and Fe of at least 1.30 wt. %, and wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2:1, In some embodiments, the aluminum alloy comprises 10 % more alpha phase particles than AA3105 aluminum alloy. In some embodiments, the aluminum alloy is a 3xxx series aluminum alloy. In some embodiments, an ultimate tensile strength of the aluminum alloy is at least 110 MPa. In some embodiments, a yield strength of the aluminum alloy is at least 50 MPa.
[0007] In some embodiments, the aluminum alloy comprises a conductivity from 40 % to 60 % based on the international annealed copper standard (IACS). In some embodiments, the aluminum ahoy comprises a corrosion potential of from -740 mV to -820 mV. In some embodiments, a fin stock comprises the aluminum alloy described herein. In some embodiments, an aluminum alloy product comprises a tube and a fin, wherein the fin comprises the aluminum alloy described herein.
[0008] In some embodiments, a method of producing an aluminum alloy product is provided. The method includes: casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.10 - 1.30 wt. % Si, 0.10 - 1.00 wt. % Fe, up to 0.30 wt. % Cu, 0.01 - 0.80 wt. % Mu, 0.20 •••• 0.80 wt. % Mg, 0.50 ••• 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al; homogenizing or annealing the cast aluminum alloy; hot rolling the cast aluminum alloy to produce a hot rolled product; and cold rolling the hot rolled product to produce to an aluminum alloy product. In some embodiments, the homogenization step comprises heating the cast aluminum alloy to a homogenization temperature from 400 °C to 600 °C at a heating rate of at least 10° C/h and soaki ng the cast aluminum alloy at the homogenization temperature for a period of time from 5 hours to 15 hours. In some embodiments, the annealing step comprises heating the cast aluminum alloy to an annealing temperature from 300 °C to 500 °C at a heating rate of at least 10 °C/h and soaking the cast aluminum alloy at the annealing temperature for a period of time from 1 hour to 8 hours. In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2: 1 and wherein the aluminum alloy product has an ultimate tensile strength of at least 110 MPa, a yield s trength of at least 50 MPa, and a conductivity of from 40 % to 60 % based on the international annealed copper standard (IACS). In some embodiments, a fin stock prepared by the method described herein.
[0009] Also provided herein are aluminum alloy products comprising the aluminum alloys described herein. The products can include a fin stock. Further provided herein are aluminum alloy products comprising a tube and a fin, wherein the fin comprises the aluminum alloys described herein. Aluminum alloy products (e.g., heat exchanger fins) obtained according to the methods are also provided herein.
[0010] Further aspects, objects, and advantages will become apparent upon consideration of the detailed description of non-limiting examples that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawing, wherein like reference numerals designate like structural elements, and in which:
[0012] FIG. 1 is a graph showing the influence of alloying elements on the thermal conductivity of an aluminum alloy.
[0013] FIG. 2 is a graph of thermodynamic calculations of the mass fraction of alpha phase particles in an aluminum alloy as a function of the amount of Si and Fe in the aluminum alloy at different temperatures according to some embodiments.
[0014] FIG. 3 is a graph of the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022) according to some embodiments.
[0015] FIGS. 4A-4C are graphs of the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022) demonstrating the effect of the Si and Fe concentration according to some embodiments.
[0016] FIGS. 5A and 5B are graphs of the electrical conductivity (% IACS) as measured by ASTM E1004 (2022) of an AA3105 aluminum alloy at various annealing temperatures for different periods of time.
[0017] FIG. 6 is a graph of the el ectrical conductivity of the sample aluminum alloys in Table 17 after heat treatment (annealing) at 375 °C for four hours according to some embodiments. [0018] FIG, 7 is a graph of the measured electrical potential difference (ΔEoc (mv)) of example 3xxx series aluminum alloys as a function of the Zn content according to some embodiments.
DETAILED DESCRIPTION
[0019] Described herein are recycle-friendly aluminum alloys which exhibit high thermal conductivity and good corrosion potential. The aluminum alloys described herein incorporate higher amounts of recycled aluminum alloy materials and less primary aluminum, as compared to AA7072 aluminum alloys used to produce fin stock, and still maintain good mechanical properties for fin stock. Specifically, the aluminum alloys described herein include a careful balance of alloying elements that surprisingly provide good thermal conductivity and corrosion potential properties despite including less prime aluminum and a higher content of solute elements than AA7072 aluminum alloys. Conventionally, higher amounts of solute elements and less prime aluminum in an aluminum alloy composition would result in poor thermal conductivity properties. For example, manganese (Mn) and other alloying elements are known to decrease thermal conductivity and ultimately the thermal efficiency of aluminum alloys. It was surprisingly found that a modified 3x.xx series aluminum alloy can include a balance of silicon (Si) and iron (Fe) to reduce the negative effects of Mnto provide good thermal conductivity properties. Additionally, the addition of zinc (Zn) to the modified 3xxx series aluminum alloy can increase the corrosion potential of the aluminum alloy. The combination of properties provides an aluminum alloy that can replace AA7072 aluminum alloys for fin stock and provides a cost-effective alternative to the use of AA7072 aluminum alloys for fin stock.
[0020] Conventional AA7072 aluminum alloy for fin stock has a strictly controlled composition to meet the minimum thermal conductivity and corrosion resistance requirements for fin stock. In general, high thermal conductivity and adequate corrosion potential, is required for aluminum alloys used to produce fin stock, which has dictated that such fin stock be fabricated from an aluminum alloy including high amounts of prime aluminum, such as AA7072 aluminum alloy. This limits the amount of recycled aluminum materials that can be used to produce AA7072 aluminum alloy. For example, AA7072 aluminum alloy cannot be produced from high amounts of recycled aluminum alloy .materials because AA7072 aluminum alloy includes Zn as the major alloying element and minor amounts of Cu, Mn, and Mg. However, recycled aluminum alloy materials may include Si, Fe, and other impurities. Due to the discrepancy between the aluminum alloy composition of AA7072 aluminum alloy and recycled aluminum alloy materials, little or no recycled aluminum alloy materials can be used to produce AA7072 aluminum alloy. This limits the amount of the recycled aluminum alloy materials that can be used to produce fin stock. Although 3xxx series aluminum alloys can include higher amounts of recycled aluminum alloy materials compared to AA7072 aluminum alloy, 3xxx series aluminum alloy generally have very poor thermal conductivity properties. Therefore, 3xxx series aluminum alloys have not been used in heat exchanger applications.
[0022] The aluminum alloys described herein can utilize higher amounts of recycled aluminum alloy materials and achieve a combination of properties for heat exchanger applications. Specifically, the aluminum alloys described herein can tolerate higher amounts of Si, Fe, and/or Cu compared to AA7072 aluminum alloy and still achieve good thermal conductivity and adequate corrosion potential properties. Additionally; the aluminum alloys described herein may include additional Zn to improve corrosion potential. The composition of the aluminum alloy described herein reduces the compositional gap between fin stock and recycled aluminum alloy materials to lower the amount of primary aluminum. By reducing the compositional gap between aluminum alloys for tin stock and recycled aluminum alloy materials, more recycled aluminum alloy may be used to produce aluminum alloys for fin stock.
[0022] The aluminum alloys described herein also possess sufficiently high thermal conductivity suitable for heat exchanger applications, and have a corrosion potential that is sufficiently negative for the fins to act in a sacrificial manner during corrosion of the heat exchanger. The aluminum alloys described herein include amounts of Zn such that the aluminum alloy can be especially useful as a sacrificial alloy (e.g., as fin stock material for use in combination with copper or aluminum alloy tubes in heat exchangers). The aluminum alloys described herein can be formed as fin stock and atached mechanically to copper or aluminum alloy tubing. The fin stock can sacrificially corrode, thus protecting the copper or aluminum alloy tubing from corrosion. The aluminum alloys described herein, can be used as fin stock in industrial applications, including in heat exchangers, or in other applications. In a heat exchanger, the aluminum alloys described herein serve as a sacrificial component, ensuring the protection of other components of the heat exch anger (e.g., a tube to which the alloy is attached). At the same time, the aluminum alloys described herein can be produced from input aluminum that is at least in part recycle-friendly. Definitions and Descriptions:
[0023] The terms “invention,” “ the invention,” “this invention,” and “the present invention” used herein are intended to refer broadly to all of the subject mater of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject mater described herein or to limit the meaning or scope of the patent claims below.
[0024] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “3xxx.” For an understanding of the n umber 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.
[0025] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.
[0026] As used herein, a plate generally has a thickness of greater than 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than 15 mm, greater than 20 nun, greater than 25 mm, greater than 30 mm, greater than 35 mm, greater than 40 mm, greater than 45 mm, greater than 50 nun, or greater than 100 mm.
[0027] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from 4 mm to 15 mm. For example, a shate may have a thickness of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.
[0028] As used herein, a sheet generally refers to an aluminum product haying a thickness of less than 4 mm. For example, a sheet may have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm.
[0029] Reference is 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 0 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 an 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. For example, the aluminum alloy can be strain hardened to various tempers, for example. H16, H18, or other H1X tempers.
[0030] The following aluminum alloys are described in terms of their elemental composition in weight percentage ( wt. %) based on the total weight of the alloy. In certain examples of each alloy, the remainder is aluminum, with a maximum wi. % of 0.15 % for the sum of the impurities.
[0031] As used herein, “electrochemical potential” or “corrosion potential” refers to a material’s amenability to a redox reaction. Electrochemical potential can be employed to evaluate resistance to corrosion of aluminum alloys described herein. A negative value can describe a material that is easier to oxidize (e.g., lose electrons or increase in oxidation state) when compared to a material with a positive electrochemical potential. A positive value can describe a material that is easier to reduce (e.g., gain electrons or decrease in oxidation state) when compared to a material with a negative electrochemical potential. Electrochemical potential, as used herein, is a vector quantity expressing magnitude and direction.
[0032] As used herein, terms such as “cast aluminum alloy,” “cast article,” 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.
[0033] As used herein, the meaning of “room temperature” can include a temperature of from 15° C to 30“ C, for example 15“ C, 16“ C, 17° C, 18° C, 19° C, 20° C, 21° C, 22° C, 23° C, 24° C, 25° C, 26° C , 27° C, 28° C, 29° C, or 30° C.
[0034] 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.
Alloy Compositions
[0035] Described below are novel aluminum alloy compositions that can be produced from recycled aluminum alloy materials. In some embodiments, the aluminum alloy is a 3xxx series aluminum alloy. For example, the aluminum alloy can be a modified AA3105 aluminum alloy. The aluminum alloys described herein exhibit high thermal conductivity and corrosion potential that is significantly improved in comparison to 3xxx series aluminum alloys, and therefore can be used for fin stock. The properties of the alloys are achieved due to the elemental compositions of the alloys, and, in some cases, also the methods of processing the alloys to produce the described sheets, plates, and shates.
[0036] As discussed herein, 3xxx series aluminum alloys generally have poor thermal conductivity and corrosion performance at least in part due to its composition. Specifically, AA3105 aluminum alloy includes high amounts of Mn (e.g., up 0.80 wt. %) and other solute elements which decreases the thermal conductivity of the AA3105 aluminum alloy. As shown in FIG. 1 , Mn in solid solution has one of the highest negative impacts on thermal conductivity per unit weight. Additionally, FIG. 1 shows that most solute elements generally decrease the thermal conductivity of the aluminum alloy. Without being bound by theory, the inventors have found that pulling Mn out of solid solution has the most beneficial impact on improving thermal conductivity of a 3xxx series aluminum alloy. The inventors have unexpectedly found that the thermal conductivity of a 3xxx series aluminum alloy can be improved by tailoring the composition of the aluminum alloy to precipitate Mn and other solute elements into constituent particles and dispersoids (e.g., Mn-containing dispersoids). By removing Mn and other solute elements from the aluminum alloy matrix, the thermal conductivity of the aluminum alloy can be increased. With the appropriate process and composition control of the main alloying additions, the resultant microstructure exhibits a high number density of dispersoids which substantially increases the thermal conductivity of the aluminum alloy. For example, the higher amount of Si and Fe in the aluminum alloy ( compared to AA3105 aluminum alloy ) increases the amount of alpha phase and beta phase particles, thereby consuming Mn (e.g., pulling the Mn out of solid solution). Specifically, the Si content (e.g., from 0.30 wt. % to 1.30 wt. %) and Fe content (e.g., from 0.10 wt. % to 1.00 wt, %) decreases the amount of Mn in solid solution by forming alpha phase particles (e.g., Al12(Fe,M n)3Si) and beta phase particles (e.g., Al1(Fe,Mn)). In this way, the aluminum alloy can be produced from recycled aluminum alloy materials (e.g., AA3105 aluminum alloy scrap).
[0037] In some embodiments, the aluminum alloys and methods described herein can be used in industrial applications including sacrificial parts, heat dissipation, packaging, and building materials. The aluminum alloys described herein can be employed as industrial fin stock for heat exchangers. The fin stock produced from the aluminum alloys described herein can be provided as a recycle-friendly alternative to AA7072 aluminum alloy that provides comparable thermal conductivity, corrosion potential, and will still preferentially conode, protecting other metal parts incorporated in a heat exchanger. [0038] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 1.
Table 1
Figure imgf000012_0001
[0039] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 2.
Table 2
Figure imgf000012_0002
[0040] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 3.
Table 3
Figure imgf000013_0001
[0041] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 4.
Table 4
Figure imgf000013_0002
[0042] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 5.
Table 5
Figure imgf000014_0001
Silicon (Si)
[0043] In some examples, the alloy includes silicon (Si) in an amount from 0.10 % to 1.30 % (e.g., from 0.20 % to 1.20 %, from 0,30 % to 1.10 %, from 0.60 % to 0.90 %, from 0,50 % to 1.00 %, from 0.60 % to 1 .00 %, or from 0.80 % to 1.30 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %. 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25
%, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36
%, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47
%, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58
%, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68
%, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80
%, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91
%, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02
%, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13
%, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24
%, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, or 1.30 % Si. All percentages are expressed in wt. %. As described above, the Si content pramotes formation of Mn-containing dispersoids to improve thermal conductivity of the aluminum alloy, thus producing a lloys that have good thermal conductivity. Specifically, Si combines with Mn and results in a high density of alpha phase particles (e.g., Al12(Fe,Mn)sSi) and/or beta phase particles (e.g., Al6(Fe,Mn)) in the al uminum alloy microstruc ture. The formation of alpha phase parti cles and beta phase particles takes free Mn out of solid solution during solidification (e.g., during casting) to reduce the negative effects of Mn on thermal conductivity. Additionally, homogenization orannealing can help pull out more Mn by growth of alpha particles and/or formation of alpha dispersoids which can further pull Mn out of solution.
Iron (Fe)
[0044] In some examples, the alloy also iron (Fe) in an amount from 0.10 % to 1.00 % (e.g., from 0,20 % to 0,90 %, from 0.30 % to 0.90 %, from 0.50 % to 0.90 %, from 0,40 % to 0.90 %, or .from 0.70 % to 1.00 %) based on the total weight of the alloy . For example, the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %,
0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %,
0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %,
0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %,
0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %,
0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %,
0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %,
0.96 %, 0.97 %, 0.98 %, 0.99 %, or 1.00 % Fe. All percentages are expressed in wt. %. In some instances, Fe and Si promotes formation of Mn-containing dispersoids to improve thermal conductivity of the aluminum alloy. As discussed above, Fe and Si can combine with Mn to produce a high density of alpha phase particles and/or beta phase particles to take free Mn out of solid solution during solidification (e.g., during casting) and after homogenization or annealing treatment to reduce the negative effects of Mn on thermal conductivity.
Copper (Cu)
[0045] In some examples, the alloy includes copper (Cu) in an amount from 0 % to 0.30 % (e.g., from 0.01 % to 0.30 %, from 0.01 % to 0.25 %, from 0.01 % to 0.20 %, or from 0.10 % to 0.30 %) based on the total weight of the alloy. For example, the alloy can include 0 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0,07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18%, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, or 0.30 % Cu. All percentages are expressed in wt. %. In some instances, a Cu content above 0.30 wt. % may lead to corrosion problems as it leads to positive corrosion potentials which is not desirable for fin stock materials.
Manganese (Mn)
[0046] In some examples, the alloy includes manganese (Mn) in an amount from 0.01 % to 0.80% (e.g., from 0.05 % to 0.70 %, from 0.10 % to 0.70 %, from 0.20 % to 0.80 %, from 0.30 % to 0.70 %, or from 0.30 % to 0.50 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19
%, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30
%, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41
%, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52
%, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63
%, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %,: 0.74
%, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, or 0.80 % Mn. All percentages are expressed in wt %. As discussed above and shown in FIG. 1, Mn has largest negative impact on thermal conductivity. Mn largely remains in solid solution while a small amount is precipitated during solidification as constituents and as dispersoids during ingot pre-heating and annealing steps. The addition of Si and Fe in the amounts described herein promotes formation of Maintaining dispersoids to limit the negative impact of Mn on thermal conductivity.
Surprisingly, the aluminum alloys described herein can achieve a balance strength due to the solid solution strengthening effects of the Mn while limiting the negative impact of Mn on thermal conductivity. Sufficient Mn, (optionally, in combination with Cu), is added to the aluminum alloy to provide strength, sagging resistance, and avoid fin erosion, but not so much to adversely affect the thermal conductivity.
Magnesium (Mg)
[0047] In some examples, the alloy included magnesium (Mg) in an amount from 0.20
% to 0.80% (e.g., from 0.20 % to 0.80 %, from 0.25 % to 0.80 %, or from 0.30 % to 0.80 %) based on the total weight of the alloy. For example, the alloy can include 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %,
0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %,
0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %,
0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %,
0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %,
0.77 %, 0.78 %, 0.79 %, or 0.80 % Mg. All percentages are expressed in wt. %. Zinc (Zn)
[0048] In some examples, the alloy includes zinc (Zn) in an amount from 0.50 % to 3.50% (e.g., from 0.50 % to 3.25 %, from 0.60 % to 3.00 %, from 0.60 % to 2.75 %, from 0.50 % to 2.50 %, from 1.00 % to 2.50 %, or from 0.70 % to 2.50%) based on the total weight of the alloy. For example, the alloy can include 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %, 1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %, 1.44 %, 1.45 %, 1.46 %, 1.47 %, 1.48 %, 1.49 %, 1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %, 1.55 %, 1.56 %, 1.57 %, 1.58 %, 1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %, 1.66 %, 1.67 %, 1.68 %, 1.69 %, 1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %, 1.77 %, 1.78 %, 1.79 %, 1.80 %, 1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %, 1.88 %, 1.89 %, 1.90 %, 1.91 %, 1.92 %, 1.93 %, 1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %, 1.99 %, 2.00 %, 2.01 %, 2.02 %, 2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %, 2.10 %, 2.11 %, 2.12 %, 2.13 %, 2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %, 2.21 %, 2.22 %, 2.23 %, 2.24 %, 2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %, 2.32 %, 2.33 %, 2.34 %, 2.35 %, 2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %, 2.43 %, 2.44 %, 2.45 %, 2.46 %, 2.47 %, 2.48 %, 2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %, 2.54 %, 2.55 %, 2.56 %, 2.57 %, 2.58 %, 2.59 %, 2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %, 2.65 %, 2.66 %, 2.67 %, 2.68 %, 2.69 %, 2.70 %, 2.71 %, 2.72 %, 2.73 %, 2.74
%, 2.75 %, 2.76 %, 2.77 %, 2.78 %, 2.79 %, 2.80 %, 2.81 %, 2.82 %, 2.83 %, 2.84 %, 2.85
%, 2.86 %, 2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %, 2.92 %, 2.93 %, 2.94 %, 2.95 %, 2.96
%, 2.97 %, 2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %, 3.03 %, 3.04 %, 3.05 %, 3.06 %, 3.07
%, 3.08 %, 3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %, 3.14 %, 3.15 %, 3.16 %, 3.17 %, 3.18
%, 3.19 %, 3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %, 3.25 %, 3.26 %, 3.27 %, 3.28 %, 3.29
%, 3.30 %, 3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %, 3.36 %, 3.37 %, 3.38 %, 3.39 %, 3.40
%, 3.41 %, 3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %, 3.47 %, 3.48 %, 3.49 %, or 3.50 % Zn.
All percentages are expressed in wt. %. The Zn content can improve the corrosion potential of the aluminum alloys described herein. Zn affects the anodic potential of aluminum alloys. Zn addition will cause an ahmunnm alloy to become more electronegative (sacrificial). In some embodiments, the Zn content of the aluminum alloys described herein is higher compared to AA3105 aluminum alloy such that the aluminum alloy will be able to act sacrificially when attached to copper or other aluminum alloy tubes, thus providing cathodic protection to the tubes. It is preferable in heat, exchanger units that the fin material is sacrificial to the tube material and that will depend on the composition of the tube material itself. By using an aluminum alloy having sufficient Zn for fin stock, the difference in corrosion potential between the tubes and fin stock can be tailored for an adequate level of protection. Specifically, when Zn is incorporated at a level as described herein, such as from 0.50 % to 3.50 %, the alloys exhibit a more adequate corrosion potential as compared to AA3105 aluminum alloy. In still further examples, Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin. For example, at Zn levels higher than those described herein, the alloys for use as fins can corrode more rapidly than for fins containing the described amount of Zn, resulting in perforations in the fin. As a result, the mechanical integrity and thermal performance of the heat exchanger can be compromised, thus affecting the service life of the heat exchanger.
Chromium (Cr)
[0049] In some examples, the alloy includes chromium (Cr) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0..16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Cr. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
Titanium (Ti)
[0050] In some examples, the alloy includes titanium (Ti) in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.1.0 %, or up to 0.05 ) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %. [0051] Optionally, the alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below; 0.03 % or below, 0.02 % or below, or 0.01 % or below each. These impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, So, Ca, Hf, Sr, or combinations thereof. Accordingly, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0,01 % or below. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt. %. In certain aspects, the remaining percen tage of the all oy is aluminum .
[0052] In some embodiments, the aluminum alloy comprises a combined content of Si and Fe of at least 0.50 % (e.g,, at least 0.60 %, at least 0.70 %, at least 0.80 %, at least 0.90 %, at least 1.00 %, at least 1.10 %, at least 1.20%, at least 1 ,25 %, at least 1.30 %, at least 1.40 %, or at least 1.50 %). In some embodiments, the aluminum alloy comprises a combined content of Si and Fe from 0.50 % to 2.30 % (e.g., from 0.50 % to 1.80 %, from 0.60 % to 2.20 %, from 0.70 % to 2.10 %, from 0.80 % to 2.00 %, from 0.90 % to 1.80 %, from 1.00 % to 2.10 %, from 1.10 % to 2.20 %, from .1.20 % to 2.00 %, or from 1.70 % to 2.30 %). All percentages are expressed in wt. %.
[0053] In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90:1 (e.g., at least 1.00:1, at least 1.20:1, at least 1.40:1, at least 1.60:1, at least 1.80:1, at least 2.0:1, at least 2.20:1, at least 2.40:1 , or at least 2.5:1). In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn from 0.90: 1 to 3.00: 1 (e.g., from 1.00: 1 to 3.00:1, from 1.20:1 to 2.90:1, from 1.10:1 to 2.80:1, from 1.20:1 to 2.75:1, from 1.25:1 to 2.60.1, from 1.40:1 to 2.50:1, or from 1.50:1 to 2.50:1).
Additional Alloy Compositions
[0054] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 6.
Table 6
Figure imgf000019_0001
Figure imgf000020_0001
[0055] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 7.
Table 7
Figure imgf000020_0002
[0056] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 8.
Table 8
Figure imgf000020_0003
Figure imgf000021_0001
[0057] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 9.
Table 9
Figure imgf000021_0002
[0058] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 10.
Table 10
Figure imgf000021_0003
Figure imgf000022_0002
[0059] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 11.
Table 11
Figure imgf000022_0003
Silicon (Si)
[0060] In some examples, the alloy includes Si in an amount from 0.40 % to 1.30 % (e.g,, from 0.50 % to 1.20 %, from 0.60 % to .1.10 %, from 0.70 % to 1,10 %, or from 0.50 % to 0.70 %) based on the total weight of the alloy. For example, the alloy can include 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0,44
Figure imgf000022_0001
0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %,
0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %,
0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %,
0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %,
0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %,
0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1,18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, or 1.30 % Si. All percentages are expressed in wt. %.
Iron (Fe)
[0061] In some examples, the alloy includes Fe in an amount from 0.50 % to 2.50 % (e.g., from 0.50 % to 2.25 %, from 0.50 % to 2.00 %, from 0.60 % to 1.80 %, from 0.70 % to 1,50 %. from 0.90 % to 1.40 %, or from 0.70 % to 1.20 %) based on the total weight of the alloy. For example, the alloy can include 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %,
0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %,
0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %,
0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %,
1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %,
1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %,
1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %,
1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %,
1.44 %, 1.45 %, 1.46 %, 1.47 %, 1.48 %, 1.49 %, 1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %,
1.55 %, 1.56 %, 1.57 %, 1.58 %, 1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %,
1.66 %, 1.67 %, 1.68 %, 1.69 %, 1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %,
1.77 %, 1.78 %, 1.79 %, 1.80 %, 1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %,
1.88 %, 1.89 %, 1.90 %, 1.91 %, 1.92 %, 1.93 %, 1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %,
1.99 %, 2.00 %, 2.01 %, 2.02 %, 2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %,
2.10 %, 2.11 %, 2.12 %, 2.13 %, 2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %,
2.21 %, 2.22 %, 2.23 %, 2.24 %, 2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %,
2.32 %, 2.33 %, 2.34 %, 2.35 %, 2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %,
2.43 %, 2.44 %, 2.45 %, 2.46 %, 2.47 %, 2.48 %, 2.49 %, or 2.50 % Fe. All percentages are expressed in wt %.
Copper (Cu)
[0062] In some examples, the alloy includes Cu in an amount from 0.10 % to 0.40 % (e.g., from 0.10 % to 0.30 %, from 0.15 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight, of the alloy. For example, the alloy can include 0.10 %. 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.40 % Cu. All percentages are expressed in wt. %. Manganese (Mn)
[0063] In some examples, the alloy includes Mn in an amount up to 1.00 % (e.g., up to 1.00 %, up io 0.90 %, up to 0.80 %, from 0.50 % to 1.00 %, from 0.50 % to 0.90 %, from 0.60 % to 0.90 %, from 0.60 % to 0.80 %, or from 0.50 % to 1.00 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15
%, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26
%, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37
%, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48
%, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59
%, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70
%, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81
%, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92
%, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, or 1.00 % Mn. In some embodiments, the aluminum alloy composition includes 0 % Mn. All percentages are expressed in wt. %.
Magnesium (Mg)
[0064] In some examples, the alloy includes Mg in an amount from 0.40 % to 0.80 % (e.g.. from 0.50 % to 0.80 %, from 0.60 % to 0.80 %, or from 0.40 % to 0.60 %) based on the total weight of the alloy. For example, the alloy can include 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %,
0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %,
0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %,
0.77 %, 0.78 %, 0.79 %, or 0.80 % Mg. All percentages are expressed in wt. %.
Zinc (Zn)
[0065] In some examples, the alloy includes Zn in an amount up to 3.50 % (e.g., up to 3.25 %, up to 3.00 %, up to 2,75 %, or up to 2.50 %) based on the total weight of the alloy. For example, the alloy can include 0.00 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0,05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %,
0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %,
0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %,
0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %,
0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %,
0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 0.83 %,
0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %,
0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %,
1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %,
1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %, 1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %,
1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %, 1.44 %, 1.45 %, 1.46 %, 1.47 %, 1.48 %, 1.49 %,
1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %, 1.55 %, 1.56 %, 1.57 %, 1.58 %, 1.59 %, 1.60 %,
1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %, 1.66 %, 1.67 %, 1.68 %, 1.69 %, 1.70 %, 1.71 %,
1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %, 1.77 %, 1.78 %, 1.79 %, 1.80 %, 1.81 %, 1.82 %,
1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %, 1.88 %, 1.89 %, 1.90 %, 1.91 %, 1.92 %, 1.93 %,
1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %, 1.99 %, 2.00 %, 2.01 %, 2.02 %, 2.03 %, 2.04 %,
2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %, 2.10 %, 2.11 %, 2.12 %, 2.13 %, 2.14 %, 2.15 %,
2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %, 2.21 %, 2.22 %, 2.23 %, 2.24 %, 2.25 %, 2.26 %,
2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %, 2.32 %, 2.33 %, 2.34 %, 2.35 %, 2.36 %, 2.37 %,
2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %, 2.43 %, 2.44 %, 2.45 %, 2.46 %, 2.47 %, 2.48 %,
2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %, 2.54 %, 2.55 %, 2.56 %, 2.57 %, 2.58 %, 2.59 %,
2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %, 2.65 %, 2.66 %, 2.67 %, 2.68 %, 2.69 %, 2.70 %,
2.71 %, 2.72 %, 2.73 %, 2.74 %, 2.75 %, 2.76 %, 2.77 %, 2.78 %, 2.79 %, 2.80 %, 2.81 %,
2.82 %, 2.83 %, 2.84 %, 2.85 %, 2.86 %, 2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %, 2.92 %,
2.93 %, 2.94 %, 2.95 %, 2.96 %, 2.97 %, 2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %, 3.03 %,
3.04 %, 3.05 %, 3.06 %, 3.07 %, 3.08 %, 3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %, 3.14 %,
3.15 %, 3.16 %, 3.17 %, 3.18 %, 3.19 %, 3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %, 3.25 %,
3.26 %, 3.27 %, 3.28 %, 3.29 %, 3.30 %, 3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %, 3.36 %,
3.37 %, 3.38 %, 3.39 %, 3.40 %, 3.41 %, 3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %, 3.47 %,
3.48 %, 3.49 %, or 3.50 % Zn. In some embodiments, the aluminum alloy composition includes 0 % Zu. All percentages are expressed in wt. %. The Zn content can optionally be provided to improve the corrosion potential of the aluminum alloys described herein. Zn can be incorporated in an aluminum alloy in an optimal amount, as described herein, to provide an alloy suitable for use as an industrial fin. In some embodiments, the aluminum alloy includes at least 1.50 wt. % Zn to provide good corrosion potential.
Chromium (Cr)
[0066] In some examples, the alloy includes Cr in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0,04 %50.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 %
Cr. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt, %.
Titanium (Ti)
[0067] In some examples, the alloy includes Ti in an amount up to 0.20 % (e.g., up to 0.15 %, up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0,14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %), All percentages are expressed in wt. %, [0068] Optionally, the alloy can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or belo w each. These impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, H f, Sr, or combinations thereof.
Accordingly, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr may be present in an alloy in amounts of 0,05 % or below, 0.04 % or below, 0,03 % or below, 0.02 % or below, or 0.01 % or below. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt, %. In certain aspects, the remaining percentage of the alloy is aluminum.
[0069] In some embodiments, the aluminum alloy composition comprises 0.50 - 0,70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt, % Cu, 0.50 — 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, up to 3.5 wt, % Zn, up to 0.05 wt, % Cr, up to 0.5 wt, % Ti, up to 0,15 wt. % of impurities, and the remainder Al.
[0070] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt, % Fe, 0.10 - 0.20 wt, % Cu, 0.50 — 1.00 wt. % Mn, 0.40 - 0.60 wt, % Mg, 0.50 - 3.50 wt. % Zn, up to 0.05 wt, % Cr, up to 0.5 wt, % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
[0071] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt % Si, 0.70 - 1,20 wt. % Fe, 0.10 - 0,20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, 0,50 — 2.00 wt, % Zn, up to 0.05 wt. % Cr, up to 0.5 wt. % Ti, up to 0,15 wt. % of impurities, and the remainder Al. [0072] In some embodiments, the aluminum alloy composi tion comprises 0.40 - 1.30 wt. % Si, 0.50 - 2.00 wt. % Fe, 0.10 - 0.40 wt % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
[0073] In some embodiments, the aluminum alloy composition comprises 0.50 - 1.20 wt. % Si, 0.60 - 1.80 wt. % Fe, 0.10 - 0.30 wt. % Cu, 0.50 - 0.90 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.25 wt. % Zn, up to 0.15 wt. % Cr, up to 0.15 wt. % Ti, up to 0, 15 wt. % of impurities, and the remainder Al.
[0074] In some embodiments, the aluminum alloy composition comprises 0.60 - 1.10 wt. % Si, 0.70 - 1.50 wt. % Fe, 0.10 - 0.30 wt. % Cu, 0.60 - 0.90 wt. % Mn, 0.50 - 0.80 wt. % Mg, up to 3.00 wt. % Zn, up to 0.10 wt. % Cr, up to 0.10 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
[0075] In some embodiments, the aluminum alloy composition comprises 0.70 - 1.10 wt. % Si, 0.90 - 1.40 wt. % Fe, 0.15 ~ 0.25 wt. % Cu, 0.60 - 0.80 wt. % Mn, 0.50 - 0.70 wt. % Mg, up to 2.75 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
[0076] In some embodiments, the aluminum alloy composition comprises 0.50 - 0.70 wt. % Si, 0.70 - 1.20 wt. % Fe, 0.10 - 0.20 wt. % Cu, 0.50 - 1.00 wt. % Mn, 0.40 - 0.60 wt. % Mg, up to 2,50 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti. up to 0.15 wt. % of impurities, and the remainder Al.
[0077] In the aforementioned embodiments, the aluminum alloy may include 0 wt. %
Zu, based on the total weight of the aluminum alloy composition. For example, in embodiments where the aluminum alloy has sufficient corrosion potential or the aluminum alloy does not require a specific corrosion potential, little or no Zn is added to the aluminum alloy.
[0078] In some embodiments, the aluminum alloy comprises a combined content of Si and Fe of at least 1.00 % (e.g., at least 1.10 %, at least 1.20%, at least 1.25 %, at least 1.30 % , at least 1.40 %, or at least 1.50 %). In some embodiments, the aluminum alloy comprises a combined content of Si and Fe from 1.00 % to 4.20 % (e.g., from 1.25 % to 4.00 %, from 1.30 % to 3.75 %, from 1.40 % to 3.50 %, from 1.50 % to 3.50 %, from 2.00 % to 4.00 %, from 2.50 % to 3.50 %, or from 3.00 % to 4.00 %). All percentages are expressed in wt. %. [0079] In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least. 1.50:1 (e.g., at least 1.60:1, at least 1.70:1, at least 1.80:1, at least 1.90:1, at least 2.0:1, at least 2.10:1, at least 2.20:1, at least 2.30:1, at least 2.40:1, or at least 2.50: 1). In some embodiments, the aluminum alloy comprises a ratio of (Si + Fe):Mn from 1.50:1 to 4.50:1 (e.g., from 1.75.T to 4.00:1, from 1.80:1 to 3.75:1, from 1.90:1 to 3.50:1, from 2.00:1 to 3.00:1, or from 1.50:1 to 2.50:1).
High Fe Aluminum Alloy Compositions
[0080] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 12.
Table 12
Figure imgf000028_0001
[0081] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 13.
Table 13
Figure imgf000028_0002
Figure imgf000029_0001
[0082] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 14.
Table 14
Figure imgf000029_0002
[0083] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 15.
Table 15
Figure imgf000029_0003
Figure imgf000030_0001
[0084] In some examples, the aluminum alloys can have the following elemental composition as provided in Table 16.
Table 16
Figure imgf000030_0002
Silico n (Si)
[0085] In some examples, the alloy includes Si in an amount from 0.10 % to 1.30 %
(e.g., from 0.20 % to 1.20 %, from 0.30 % to 1.10 %, from 0.60 % to 0.90 %, from 0.50 % to 1.00 %, from 0.60 % to 1.00 %, or from 0.80 % to 1.30 %) based on the total weight of the alloy. For example, the alloy can Include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %,
0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %,
0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %,
0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %,
0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %,
0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %,
0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %,
0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, or 1.30 % Si. All percentages are expressed in wt. %.
Iron (Fe)
[0086] In some examples, the alloy includes Fe in an amount from 0.10 % to 2.50 % (e.g., from 0.50 % to 2.25 %, from 0.60 % to 2.00 %, from 0.75 % to 2.00 %, from 0.80 % to 2.00 %, from 0.90 % to 2.00%, or from 1 .00 % to 2.00 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0,15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %. 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %,
0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %,
0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %,
0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %,
0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %,
0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %,
0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %,
0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %,
1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %,
1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %,
1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %, 1.33 %, 1.34 %, 1.35 %, 1.36 %,
1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %, 1.44 %, 1.45 %, 1.46 %, 1.47 %,
1.48 %, 1.49 %, 1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %, 1.55 %, 1.56 %, 1.57 %, 1.58 %,
1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %, 1.66 %, 1.67 %, 1.68 %, 1.69 %,
1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %, 1.77 %, 1.78 %, 1.79 %, 1.80 %,
1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %, 1.88 %, 1.89 %, 1.90 %, 1.91 %,
1.92 %, 1.93 %, 1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %, 1.99 %, 2.00 %, 2.01 %, 2.02 %,
2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %, 2.10 %, 2.11 %, 2.12 %, 2.13 %,
2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %, 2.21 %, 2.22 %, 2.23 %, 2.24 %,
2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %, 2.32 %, 2.33 %, 2.34 %, 2.35 %,
2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %, 2.43 %, 2.44 %, 2.45 %, 2.46 %,
2.47 %, 2.48 %, 2.49 %, or 2.50 % Fe. All percentages are expressed in wt. %.
Copper (Cu)
[0087] In some examples, the alloy includes Cu in an amount from 0 % to 0.30 % (e.g., from 0.01 % to 030 %, from 0.01 % to 0.25 %, from 0.01 % to 0.20 %, or from 0.10 % to 0.30 %) based on the total weight of the alloy. For example, the alloy can include 0 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0. 10 %, 0. 11 %, 0. 12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, or 0.30 % Co. All percentages are expressed in wt. %.
Manganese (Mn)
[0088] In some examples, the alloy included Mn in an amount from 0.01 % to 0.80% (e.g., from 0.05 % to 0.70 %, from 0.10 % to 0.70 %, from 0.20 % to 0.80 %, from 0.30 % to 0.70 %, or from 0.30 % to 0.50 %) based on the total weight of the alloy,. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %,
0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %,
0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %,
0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %,
0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %,
0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %,
0.76 %, 0.77 %, 0/78 %, 0.79 %, or 0.80 % Mn. All percentages are expressed in wt. %.
[0089] In some examples, the alloy includes Mg in an amount from 0.20 % to 0,80% (e.g., from 0.20 % to 0.80 %, from 0.25 % to 0.80 %, or from 0.30 % to 0.80 %) based on the total weight of the alloy. For example, the alloy can include 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %,
0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %,
0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %,
0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %,
0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %,
0.79 %, or 0.80 % Mg. All percentages are expressed in wt. %.
Zinc (Zn)
[0090] In some examples, the alloy includes Zn in an amount from 0.50 % to 3.50% (e.g., from 0.50 % to 3.25 %, from 0.60 % to 3.00 %, from 0.60 % to 2.75 %, from 0.50 % to 2.50 %, from 1.00 % to 2.50 %, or from 0.70 % to 2.50%) based on the total weight of the alloy. For example, the alloy can include 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %. 0.55 %,
0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %,
0.67 %, 0.68 %, 0.68 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %,
0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.10 %,
1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.20 %, 1.21 %,
1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.30 %, 1.31 %, 1.32 %,
1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.38 %, 1.39 %, 1.40 %, 1.41 %, 1.42 %, 1.43 %,
1.44 %, 1.45 %, 1.46 %, 1.47 %, 1.48 %, 1.49 %, 1.50 %, 1.51 %, 1.52 %, 1.53 %, 1.54 %,
1.55 %, 1.56 %, 1.57 %, 1.58 %, 1.59 %, 1.60 %, 1.61 %, 1.62 %, 1.63 %, 1.64 %, 1.65 %,
1.66 %, 1.67 %, 1.68 %, 1.69 %, 1.70 %, 1.71 %, 1.72 %, 1.73 %, 1.74 %, 1.75 %, 1.76 %,
1.77 %, 1.78 %, 1.79 %, 1.80 %, 1.81 %, 1.82 %, 1.83 %, 1.84 %, 1.85 %, 1.86 %, 1.87 %,
1.88 %, 1.89 %, 1.90 %, 1.91 %, 1.92 %, 1.93 %, 1.94 %, 1.95 %, 1.96 %, 1.97 %, 1.98 %,
1.99 %, 2.00 %, 2.01 %, 2.02 %, 2.03 %, 2.04 %, 2.05 %, 2.06 %, 2.07 %, 2.08 %, 2.09 %,
2.10 %, 2.11 %, 2.12 %, 2.13 %, 2.14 %, 2.15 %, 2.16 %, 2.17 %, 2.18 %, 2.19 %, 2.20 %,
2.21 %, 2.22 %, 2.23 %, 2.24 %, 2.25 %, 2.26 %, 2.27 %, 2.28 %, 2.29 %, 2.30 %, 2.31 %,
2.32 %, 2.33 %, 2.34 %, 2.35 %, 2.36 %, 2.37 %, 2.38 %, 2.39 %, 2.40 %, 2.41 %, 2.42 %,
2.43 %, 2.44 %, 2.45 %, 2.46 %, 2.47 %, 2.48 %, 2.49 %, 2.50 %, 2.51 %, 2.52 %, 2.53 %,
2.54 %, 2.55 %, 2.56 %, 2.57 %, 2.58 %, 2.59 %, 2.60 %, 2.61 %, 2.62 %, 2.63 %, 2.64 %,
2.65 %, 2.66 %, 2.67 %, 2.68 %, 2.69 %, 2.70 %, 2.71 %, 2.72 %, 2.73 %, 2.74 %, 2.75 %,
2.76 %, 2.77 %, 2.78 %, 2.79 %, 2.80 %, 2.81 %, 2.82 %, 2.83 %, 2.84 %, 2.85 %, 2.86 %,
2.87 %, 2.88 %, 2.89 %, 2.90 %, 2.91 %, 2.92 %, 2.93 %, 2.94 %, 2.95 %, 2.96 %, 2.97 %,
2.98 %, 2.99 %, 3.00 %, 3.01 %, 3.02 %, 3.03 %, 3.04 %, 3.05 %, 3.06 %, 3.07 %, 3.08 %,
3.09 %, 3.10 %, 3.11 %, 3.12 %, 3.13 %, 3.14 %, 3.15 %, 3.16 %, 3.17 %, 3.18 %, 3.19 %,
3.20 %, 3.21 %, 3.22 %, 3.23 %, 3.24 %, 3.25 %, 3.26 %, 3.27 %, 3.28 %, 3.29 %, 3.30 %,
3.31 %, 3.32 %, 3.33 %, 3.34 %, 3.35 %, 3.36 %, 3.37 %, 3.38 %, 3.39 %, 3.40 %, 3.41 %,
3.42 %, 3.43 %, 3.44 %, 3.45 %, 3.46 %, 3.47 %, 3.48 %, 3.49 %, or 3.50 % Zn. All percentages are expressed in wt. %.
Chromium (Cr)
[0091] In some examples, the alloy includes chromium (Cr) in an amount up to 0.20 % (e.g., up to 0.15 up to 0.10 %, or up to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08
%, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Cr. In some cases, Cr is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
Titanium (Ti) [0692] In some examples, the alloy includes titanium (Ti) in an amount up to 0.20 % (e.g., up to 0.15 up to 0.10 %, or up to 0.05 ) based on the total weight of the alloy. For example, the alloy can include 0.001 %. 0.002 %, 0.003 %, 0.004 %, 0.005 %, 0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.1.4 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.1.9 %, or 0.20 % Ti. In some cases, Ti is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
[0093] Optionally, the alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below each. These impurities may include, but are not limited to, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, Sr, or combinations thereof. Accordingly, Na, Ga, V, Ni, Sc, Ag, B, Bi, Zr, Li, Pb, Sn, Ca, Hf, or Sr maybe present in an alloy in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below. In certain aspects, the sum of all impurities does not exceed 0...15 % (e.g., 0.1 %). AH percentages are expressed in wt. %.. In certain aspects, the remaining percentage of the alloy is aluminum. Recycled Content
[0094] The aluminum alloys described herein can tolerate higher amounts of recycled aluminum alloy materials and still exhibit desirable mechanical properties. The impact of the impurities and/or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing a tailored aluminum alloy composition to compensate for the impurities. This enables a higher amount of less expensi ve, higher impurity recycled aluminum alloy materials (e.g., used 3xxx series aluminum alloy) for producing aluminum alloys that can still exhibit desirable properties. The aluminum alloy compositions described herein can include higher amounts of recycled aluminum alloy ma terials compared to AA7072 aluminum alloy with little or no additional primary aluminum.
[0095] In some embodiments, the aluminum alloy composition described herein provides a composition that is well-suited for utilizing used AA3105 aluminum alloy scrap as recycle material. In some embodiments, the aluminum alloy composition described herein can utilize UBC scrap. UBC scrap is a mixture of various aluminum alloys (e.g... from different aluminum alloys used for can bodies and can ends). UBC scrap generally includes a mixture of metal from various aluminum alloys, such as metal from can bodies (e.g., AA3104, AA3004, or other 3xxx series aluminum alloys) and can ends (e.g., AA5182 or other 5xxx series aluminum alloys). UBC scrap can be shredded and de-coated or de- lacquered prior to being melted for use as liquid metal stock in casting a new metal product. [0096] As discussed herein, the aluminum alloy composition described herein can utilize recycled aluminum alloy materials (e.g., used AA3105 aluminum alloy scrap) to produce the aluminum alloy due to the aluminum alloy composition. This allows the use of more recycled aluminum alloy materials for producing fin end stock and reduces the amount of primary aluminum. In some aspects, the aluminum alloys described herein include a high amount of recycled aluminum alloy materials scrap at or greater than 25 %, e.g., at or greater than 30 %, at or greater than 35 %, at or greater than 40 %, at or greater than 45 %, at or greater than 50 %, at or greater than 55 %, at or greater than 60 %, at or greater than 65 %, at or greater than 70 %, or at or greater than 75 %, In terms of ranges, the aluminum alloys described herein can include from 25 % to 90 % recycled aluminum alloy materials (e.g., from 25 % to 85 %, from 30 % to 80 %, from 35 % to 75 %, from 40 % to 70 %, from 50 % to 70 %, or from 35 % to 50 %). As discussed above, in some aspects the aluminum alloys described herein are particularly well-suited to utilize used AA3105 aluminum alloy scrap. [0097] In some aspects, the aluminum alloys described herein include less than 30 % primary ahtminum, e.g., less than 30 %, less than 29 %, less than 28 %, less than 27 %, less than 26 %, less than 25 %, less than 24 %, less than 23 %, less than 22 %, less than 21 %, or less than 20 %. All are expressed in wt. %.
Alloy Properties
[0098] The processes of producing aluminum al loys described herein lead to an aluminum material that can be described as “strain-hardened,” “cold-worked,” and/or having or being in “H1X” temper (e.g., H16 temper). The mechanical properties of the aluminum alloy can be controlled by various processing conditions depending on the desired use. The alloy can be produced (or provided) in an H temper (e.g., HX1, HX2, HX3, HX4, HX5, HX6. HX7, HX8, or HX9 tempers). As one example, the alloy can be produced (or provided) in the Hix or H2x temper. It is to be understood that a particular range of properties is associated with the temper designation.
[0099] In some embodiments, the aluminum alloys described herein have high strength, corrosion potential, and thermal conductivity in the H tempers (e.g., H1x or H2x temper). In some embodiments, the aluminum alloys described herein have adequate corrosion potential in the H tempers (e.g., H16 temper). As a. result of controlling the composition and microstructure as described herein, the aluminum alloys described herein exhibit the following balance of properties.
[00100] In some embodiments, the aluminum alloys can have a yield strength (YS) of at least 50 MPa. In non-limiting examples, the yield strength is at least 50 MPa, at least 60 MPa, at least 70 MPa, at least 80 MPa, at least 90 MPa, at least 100 MPa, at least 110 MPa, at least 120 M Pa, at least 130 M Pa, at least 140 MPa, at least 150 MPa, or at least 160 MPa, or anywhere in between. In some cases, the yield strength is from 50 MPa to 180 MPa. For example, the yield strength can be from 55 M Pa to 175 MPa, from 60 MPa to 170 M Pa, from 65 MPa to 165 MPa, from 70 MPa to 160 MPa. or from 75 MPa to 170 MPa.
[00101] The yield strength will vary based on the tempers of the alloys. In some examples, the alloys described herein provided in an H temper can have a yield strength of from at least 100 MPa to 170 MPa. In non-limiting examples, the yield strength of the alloys in H temper is at least 110 MPa, at least 120 MPa, at least 125 MPa, at least 130 MPa, at least 135 MPa, at least 140 MPa, at least 145 MPa, at least 150 MPa, at least 155 MPa. at least 160 MPa, at least 165 M Pa, at least 170 MPa, or anywhere in between.
[00102] In some embodiments, the aluminum alloys described herein can have an ultimate tensile strength (UTS) of at least 110 MPa. In non-limiting examples, the yield strength is at least 110 MPa, at least 120 MPa, at least 130 MPa, at least 140 MPa, at least 150 MPa, at least 160 M Pa, at least 170 MPa, at least 180 MPa, at least 190 MPa, at least 200 MPa, or anywhere in between. In some cases, the yield strength is from 110 MPa to 240 MPa. For example, the yield strength can be from 115 M Pa to 235 MPa, from 125 MPa to 230 MPa, from 130 MPa to 225 MPa, from 140 MPa to 220 MPa, or from 150 MPa to 240 MPa.
[00103] In some embodiments, the aluminum alloys described herein provided in an H temper can have an UTS of from at least 140 MPa to 200 .MPa. In non-limiting examples, the UTS of the alloys in H temper is at least 140 MPa, at least 145 MPa, at least 150 MPa, at least 155 MPa, at least 160 MPa, at least 165 MPa, at least 170 MPa, at least 175 MPa, at least 180 MPa, at least 190 MPa, or anywhere in between.
[00104] In some embodiments, the aluminum alloys described herein have sufficient formability to meet an elongation of 2 % or greater. In certain examples, the alloys described herein can have an elongation of 2 % or greater, 2.25 % or greater, 2.50 % or greater, 2.75 % or greater, 3 % or greater, 3.25 % or greater, 3.50 % or greater, 3.75 % or greater, 4 % or greater, 4.25 % or greater, 4.50 % or greater, 4,75 % or greater, 5.0 % or greater, 5.25 % or greater, 5.50 % or greater, 5.75 % or greater, 6.0 % or greater, or anywhere in between. [00105] In some embodiments, the aluminum alloys described herein can have an average conductivity val ue of above 40 % based on the international annealed copper standard (IACS) (e.g., from 40 % IACS to 60 % IACS). For example, the alloy can have an average conductivity value of 40 %, 41 %, 42 %, 43 %, 44 %, 45 %, 46 %, 47 %, 48 %, 49 %, 50 %, 51 %, 52 %, 53 %, 54 %, 55 %, 56 %, 57 %, 58 %, 59 %, 60 %, or anywhere in between. All values in % (ACS.
[00106] In some embodiments, the aluminum alloys described herein can have a corrosion resistance that provides a negative corrosion potential or electrochemical potential (Ecorr) of -from -740mV to -820mV when tested according to the ASTM G69 standard. In certain cases, an open corrosion potential value vs. Standard Calomel Electrode (SCE) can be from - 740mV to -820mV (e.g., from -745 mV to -785 mV or from -755 mV to -790 mV), In certain cases, an open corrosion potential value vs, SCE can be -740mV, -750mV, -760mV, -770mV, -780mV, -790mV, -800mV, -810mV. or -820mV.
Methods of Preparing and Processing
[00107] In some embodiments, the properties of the aluminum alloy described herein is at least partially determined by the method of producing the aluminum alloy. Without, intending to limit the disclosure, aluminum alloy properties are partially determined by the formation of microstructures during the alloy’s preparation. In certain aspects, the method of preparation for an alloy composition may influence or even determine whether the alloy will have properties adequate for a desired application.
[00108] In some embodiments, the method of producing the aluminum alloy described herein can improve thermal conductivity of the aluminum alloy. For example, the method may include a homogenization or annealing practice that can promote growth and coarsening of Mn-containing dispersoids (e.g., alpha phase particles). Additionally, the homogenization or annealing practice can beneficially transform beta phase particles into alpha phase particles, which have a higher content of M.n than beta phase particles. In this way, the homogenization or annealing practice can be optimized to maximize the thermal conductivity of the aluminum alloy by taking M n out of solid solution.
Casting
[00109] The alloy described herein can be cast using a casting method as known to those of skill in the art. For example, the casting process can include a continuous (CC) casting process to produce a cast aluminum alloy. The CC process may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters. In some embodiments, the casting process is performed by a CC process to form a cast aluminum alloy in the form of a billet, a slab, a shate, a strip, and the like. Optionally, the casting process can include a direct chill casting (DC) process.
[00110] The cast aluminum alloy can then be subjected to further processing steps. For example, the processing methods as described herein can include the steps of homogenization/annealing, hot rolling, cold rolling, and/or annealing.
Homogenization or Annealing
[00111] Following the casting step, a homogenization step or annealing step can be performed. In some embodiments, the annealing step is used for contmuous casting processes. For example, for a cast aluminum alloy produced from a continuous casting process may be annealed and is not homogenized.
[00112] The homogenization step can include heating a cast aluminum alloy to a peak metal temperature of at least 400° C (e.g., at least 410° C, at least 420° C, at least 430° C, at least 440° C, at least 450° C, at least 460° C, at least 470° C, at least 480° C, at least 490° C, at least 500° C, at least 510° C, at least 520° C, at least 530° C, at least 540° C, at least 450° C, at least 460° C, at least 470° C, at least 480° C, at least 490° C, or at least 500° C). For example, the cast aluminum alloy can be heated to a peak metal temperature of from 400° C to 600° C (e.g., from 425° C to 600° C, from 450° C to 600° C, from 500° C to 600° C, from 500° C to 580° C, or from 500° C to 575° C). In some cases, the heating rate to the peak metal temperature can be 10° C/hour or greater (e.g., 20° C/hour or greater, 30° C/hour or greater, 40° C/hour or greater, 50° C/hour or greater, 60° C/hour or greater. 70° C/hour or greater, 80° C/hour or greater, 90° C/hour or greater, or 100° C/hour or greater). In other cases, the heating rate to the peak metal temperature can be from 10°- C/hour to 250° C/hour (e.g., 20° C/hour to 250° C/hour, 40° C/hour to 225° C/hour, 60° C/hour to 220° C/hour, from 80° C/hour to 200° C/hour, from 100° C/hour to 200° C/hour, or from 100° C/hour to 250° C/hour).
[00113] The cast aluminum alloy is then allowed to soak (i.e., held at the indicated temperature) for a period of time at the peak metal temperature range. According to one non- limiting example, the cast aluminum alloy is allowed to soak for up to 20 hours (e.g., from 1 hour to 18 hours or from 6 hours to 15 hours). For example, the cast aluminum alloy can be soaked at the peak metal temperature from 500° C to 600° C for 1 hour, 2 hours. 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, or 20 hours. In some embodiments, the cast aluminum alloy is heated to a peak metal temperature from 500° C to 600° C at a heating rate of least 10° C/hour and soaked at the peak metal temperature for 6 hours to 15 hours.
[00114] In some embodiments, the homogenization described herein can be carried out in a two-stage process. In such embodiments, the two-stage process can include the above- described heating and soaking steps, which can be referred to as the first stage, and can further inchide a second stage. In the second stage, the temperature of the cast aluminumalloy is increased to a temperature higher than the temperature used for the first stage. For example, the temperature for the second stage can be increased, for example, to a temperature at least 5° C higher than the peak metal temperature during the first stage. For example, the peak metal temperature can be increased to a temperature of at least 455" C (e.g., at least 460° C, at least 465° C, or at least 470° C). The heating rate to the second stage temperature can be 5° C/hour or less, 3° C/hour or less, or 2.5° C/hour or less. The cast aluminum alloy is then allowed to soak for a period of time during the second stage. In some embodiments, the cast aluminum alloy is allowed to soak for up to 10 hours (e.g., from 30 minutes to 10 hours, inclusively). For example, the cast aluminum alloy can be soaked in the second stage for 30 minutes, for 1 hour, for 2 hours, for 3 hours, for 4 hours, for 5 hours, for 6 hours, for 7 hours, for 8 hours, for 9 hours, or for 10 hours. In some embodiments, following homogenization , the aluminum alloy cast product is allowed to cool to room temperature.
[00115] In some embodiments, following the casting step, an annealing step can be performed. The annealing step can include heating a cast aluminum alloy to an annealing temperature of at least 300° C (e.g., at least 310° C, at least 320° C, at least 330° C, at least 340° C, at least 350° C, at least 360° C, at least 370° C, at least 380° C, at least 390° C, at least 400° C, at least 410° C, at least 420° C, at least 430° C, at least.440° C, or at least 450° C). For example, the cast aluminum alloy can be heated to an annealing temperature of from 300° C to 500° C (e.g., from 325° C to 500° C, from 350° C to 500° C, from 300° C to 450° C, from 350° C to 450° C, from 300° C to 400° C, or from 400° C to 500° C). In some cases, the heating rate to the annealing temperature can be 10° C/hour or greater (e.g., 20° C/hour or greater, 30° C/hour or greater, 40° C/hour or greater, 50° C/hour or greater, 60° C/hour or greater, or 70° C/hour or greater). In other cases, the heating rate to the annealing temperature can be from 10° C/hour to 250° C/hour (e.g., 20° C/hour to 250° C/hour, 40° C/hour to 225° C/hour, 60° C/hour to 220° C/hour, from 80° C/hour to 200° C/hour, from 100° C/hour to 200° C/hour, or from 100° C/hour to 250° C/hour).
[00116] The cast aluminum alloy is then allowed to soak (i.e., held at the indicated temperature) for a period of time at the annealing temperature range. According to one non- limiting example, the cast aluminum alloy is allowed to soak for up to 10 hours (e.g., from 30 minutes to 9 hours or 3 hours to 6 hours). For example, the cast aluminum alloy can be soaked at the annealing temperature from 300° C to 500° C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours. 8 hours, 9 hours, 10 hours, or anywhere in between. In some embodiments, the cast aluminum alloy is heated to an annealing temperature from 300° C to 500° C at a heating rate of least 10° C/hour and soaked at the annealing temperature for 6 hours to 15 hours.
[00117] The homogenization step or annealing step described herein can promote growth and coarsening of Mn-containing dispersoids (e.g., alpha particles). Additionally, the homogenization practice or annealing practice can beneficially transform beta phase particles into alpha phase particles, which have a higher content of Mn than beta phase particles. In this way, the homogenization step or annealing step can be optimized to maximize the thermal conductivity of the aluminum alloy by taking Mn out of solid solution.
Hot Rolling
[00118] Follo wing the homogenization step or annealing step, a hot rolling step can be performed to produce a hot rolled product. The cast aluminum alloy can be hot rolled to produce a hot rolled product at a temperature from 450° C to 560° C (e.g., from 460° C to 550° C, from 470° C to 540° C, from 480° C to 530° C, or from 490° C to 520° C). la some examples, the hot rolling temperature is 450° C, 460° C. 470° C, 480° C, 490° C, 500° C, 510° C , 520° C, 530° C, 540° C, 550° C or 560° C. If the hot rolling temperature is too cold (e.g., less than 450° C), die hot roll loads are too high and may be susceptible to cracking. If the hot rolling temperature is too hot (e.g., greater than 560° C), the aluminum alloy may be too soft and break up in the hot rolling mill.
[00119] In certain cases, the cast aluminum alloy can be hot rolled to a 2 mm to 15 mm thick gauge (e.g., from 2.5 mtn to 12 rum thick gauge). For example, the cast aluminum alloy can be hot rolled to an 2 mm thick gauge, 2.5 mm thick gauge, 3 mm thick gauge, 3.5 mm thick gauge, 4 mm thick gauge, 5 mm thick gauge, 6 mm thick gauge, 7 mm thick gauge, 8 mm thick gauge, 9 mm thick gauge, 10 mm thick gauge, 11 mm thick gauge, 12 mm thick gauge, 13 mm thick gauge, 14 mm thick gauge, or 15 mm thick gauge. In certain cases, the cast aluminum alloy can be hot rolled to a gauge greater than 15 mm (i.e., a plate). In other cases, the cast aluminum alloy can be hot rolled to a gauge less than 4 mm (i.e., a sheet).
Cold Rolling [00120] Following the hot rolling step, a cold rolling step can be performed. The cold rolling step can include one or more cold rolling passes. In certain embodiments, the hot rolled product from the hot rolling step (e.g., the plate, shate, or sheet) can be cold rolled to a thin-gauge shate or sheet. In some embodiments, this thin-gauge shate or sheet is cold rolled to have a thickness (i.e. , a first thickness) ranging from 1.0 mm to 10.0 mm, or .from 2.0 mm to 8.0 mm, or from 3.0 mm to 6.0 mm, or from 4.0 mm to 5.0 mm. In some embodiments, this thin-gauge shate or sheet is cold rolled to have a thickness of 12.0 mm, 11.9 mm, 11.8 mm, 11.7 mm, 11.6 mm, 11.5 mm, 11.4 mm, 11.3 mm, 11.2 mm, 11.1 mm, 11.0 mm, 10.9 mm, 10.8 mm, 10.7 mm, 10.6 mm, 10.5 mm, 10.4 mm, 10.3 mm, 10.2 mm, 10.1 mm, 10.0 mm, 9.9 mm, 9.8 mm, 9.7 mm, 9.6 mm, 9.5 mm, 9.4 mm, 9.3 mm, 9.2 mm, 9.1 mm, 9.0 mm, 8.9 mm, 8.8 mm, 8.7 mm, 8.6 mm, 8.5 mm, 8.4 mm, 8.3 mm, 8.2 mm, 8.1 mm, 8.0 mm, 7.9 mm, 7.8 mm, 7.7 mm, 7.6 mm, 7.5 mm, 7.4 mm, 7.3 mm, 7.2 mm, 7.1 mm, 7.0 mm, 6.9 mm, 6.8 mm, 6.7 mm, 6.6 mm, 6.5 mm, 6.4 mm, 6.3 mm, 6.2 mm, 6.1 mm, 6.0 mm, 5.9 mm, 5.8 mm, 5.7 mm, 5.6 mm, 5.5 mm, 5.4 mm, 5.3 mm, 5.2 mm, 5.1 mm, 5.0 mm, 4.9 mm, 4.8 mm, 4.7 mm, 4.6 mm, 4.5 mm, 4.4 mm, 4.3 mm, 4.2 mm, 4.1 mm, 4.0 mm, 3.9 mm, 3.8 mm, 3.7 mm, 3.6 mm, 3.5 mm, 3.4 mm, 3.3 mm, 3.2 mm, 3.1 mm, 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm, 2.0 mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0,8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm, or 0.1 mm.
[00121] In some embodiments, the one or more cold rolling passes reduce the thickness of the hot rolled product by at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, or at least 70%. In some embodiments, the one or more cold rolling passes reduces the hot rolled product to a thickness (i.e., a first thickness) of no more than 10 mm, no more than 9 mm, no more than 8 mm, no more than 7 mm, no more than 6 mm, or no more than 5 mm.
[00122] In some examples, the cold rolling step is a two-stage cold rolling step. The two- stage cold rolling step can comprise a first cold rolling step, an optional intervening inter- annealing step, and a second cold rolling step. Optionally, the method can further comprise annealing the rolled product after the second cold rolling step.
Optional Inter-Annealing
[00123] In some non-limiting examples, an optional inter-annealing step can be performed during the two-stage cold rolling step. For example, the hot rolled product can be cold rolled to an intermediate gauge aluminum alloy product (first cold rolling step), annealed, and subsequently cold rolled to a final gauge aluminum alloy product (second cold rolling step). In some aspects, the optional inter-annealing can be performed in a batch process (i.e., a batch inter-annealing step) or in a continuous process. The inter-annealing step can be performed at a temperature of from 250° C to 450° C (e.g., 250° C, 260° C, 270° C, 280° C, 290° C, 300° C, 310° C, 320° C, 330° C, 340° C, 350° C, 360° C, 370° C, 380° C, 390° C, 400° C, 410° C, 420° C, 430° C, 440° C, or 450° C).
[00124] In some cases, the heating rate in the inter-annealing step can be 100° C/hour or less, 75° C/hour or less, 50° C/hour or less, 40° C/hour or less, 30° C/hour or less, 25° C/hour or less, 20° C/hour or less, or 15° C/hour or less. In other cases, the heating rate can be from 10° C/hour to 100° C/hour (e.g., from 10° C/hour to 90° C/hour , from 1 0° C/hour to 70° C/hour , from 10° C/hour to 60° C/hour, from 20° C/hour to 90° C/hour, from 30° C/hour to 80° C/hour , from 40° C/hour to 70° C/hour , or from 50° C/hour to 60° C/hour),
[00125] In some embodiments, the cold rolled product is allowed to soak for a period of time during the inter-annealing step. In some examples, the cold rolled product is allowed to soak for up to 5 hours (e.g., from 30 minutes to 4 hours, from 45 minutes to 3 hours, or from 1 hour to 2 hours, inclusively). For example, the cold rolled product can be soaked at a temperature of from 250° C to 450° C for 20 minutes. 30 minutes, 45 minutes, 1 hour, 1.5 hours, 2 hours, 3 hours, 4 hours, 5 hours, or anywhere in between. In some examples, the cold rolled product can be soaked at a temperature of 400° C for 4 hours.
Ahminum Alloy Microstructure
[00126] The aluminum alloys described herein when produced according to the methods described herein include dispersoids that result in improved mechanical properties. For example, the aluminum alloys described herein includes higher amoun t of Si and Fe compared to AA3105 aluminum alloy to produce greater amounts of Mn-containing dispersoids. As discussed herein. Mn in solid solution has the greatest negative impact on thermal conductivity. The aluminum alloy composition in combination with the method of producing the aluminum alloy promotes formations of alpha phase particles that decreases the amount of Mn in solid solution. In some embodiments, the amounts of Si and Fe in the aluminum alloys described herein results in higher amounts of alpha phase particles (e.g., Al12(Fe,Mn)3Si)) compared to AA3105 aluminum alloy. Moreover, the homogenization or annealing practice described herein promotes growth and coarsening ofMn-containing dispersoids (e.g., alpha phase particles) and converts beta phase particles into alpha phase particles, which have a higher content of Mn than beta phase particles. In this way, the homogenization or annealing practice can be optimized to maximize the thermal conductivity of the aluminum alloy by removing Mn from solid solution.
[00127] In some embodiments, the aluminum alloys described herein when produced according to the methods described herein includes greater than 5 % of alpha phase particles compared to AA3105 aluminum alloy (e.g., greater than 6 % greater than 7 %, greater than 8 %, greater than 9 %, greater than 10 %, greater than 11 %, greater than 12 %, greater than 13 %, greater than 14%, or greater than 15 %). In some embodiments, the aluminum alloys described herein when produced according to the methods described herein includes from 5 % to 30 % more alpha phase particles compared to AA3105 aluminum alloy (e.g.. from 6 % to 28 %, from 8 % to 26 %, from 10 % to 25 %, from 12 % to 25 %, from 15 % to 25 %, or from 10 % to 20 %),
[00128] In some embodiments, the aluminum alloys described herein when produced according to the methods described herein includes less than 20 % of beta phase particles compared to AA3105 aluminum alloy (e.g., less than 18 %, less than 16 %, less than 15 %, less than 14 %, less than 12 %, or less than 10 %). In some embodiments, the aluminum alloys described herein when produced according to the methods described herein includes from 2 % to 30 % less beta phase particles compared to AA3105 aluminum alloy (e.g., from 2 % to 28 %, from 4 % to 26 %, from 5 % to 25 %, from 8 % to 22 %, from 8 % to 15 %, or from 10 % to 15 %).
Methods of Using
[00129] The aluminum alloys and methods described herein can be used in industrial applications including sacrificial parts, heat dissipation, packaging, and building materials. The aluminum alloys described herein can be used in various applications, for example, for manufacturing fins for heat exchangers. In one example, the improved aluminum alloys described herein are useful for high performance, light weight automotive heat exchangers. More generally, the aluminum alloys described herein can be used in motor vehicle heat exchangers such as radiators, condensers and evaporators. As discussed above, the compositions and the processes for producing the improved aluminum alloys described herein lead to a material possessing a combination of beneficial characteristics and properties that make it suitable for manufacturing heat exchanger fins. However, the uses and applications of the improved aluminum alloys described herein are not limited to automotive heat exchangers and other uses are envisioned. It is to be understood that the characteristics and properties of the aluminum alloys described herein can also be beneficial for uses and applications other than the production of automotive heat exchanger fins. For example, the improved aluminum alloys described herein can be used for manufacture of various devices employing heat exchangers and produced by joined parts, such as devices employed in heating, ventilation, and air conditioning (HVAC).
[00130] The aluminum alloys disclosed herein are suitable substitutes for metals conventionally used in indoor and outdoor HVAC units. As used herein, the meaning of “indoor” refers to a placement contained within any structure produced by humans with controlled environmental conditions. As used herein, the meaning of “outdoor” refers to a placement not fully contained within any structure produced by humans and exposed to geological and. meteorological environmental conditions comprising air, solar radiation, wind, rain, sleet, snow, freezing rain, ice, hail, dust storms, humidity, aridity, smoke (e.g., tobacco smoke, house fire smoke, industrial incinerator smoke and wild fire smoke), smog, fossil feel exhaust, bio-fuel exhaust, salts (e.g., high salt content air in regions near a body of salt water), radioactivity, electromagnetic waves, corrosive gases, corrosive liquids, galvanic metals, galvanic alloys, corrosive solids, plasma, fire, electrostatic discharge (e.g., lightning), biological materials (e.g., animal waste, saliva, excreted oils, vegetation), wind-blown particulates, barometric pressure change, and diurnal temperature change. The aluminum alloys described herein provide better corrosion performance and higher strength as compared to alloys currently employed.
[00131] In some embodiments, the aluminum alloys described herein can be used in busbars, for example, as a conductive busbar. As used herein, “busbars” generally refer to a metal strip or bar used to carry current, tor example, for power distribution. In some embodiments, the aluminum alloys described herein can be used to produce transformers or portions of transformers. The high electrical conductivity of the aluminum alloy make these alloys particularly suitable for producing busbars and transformers.
Illustrations
[00132] Illustration 1: An aluminum alloy comprising 0,10 - 1.30 wt. % Si, 0.10 - 1.00 wt. % Fe, up to 0.30 wt. % Cu, 0.01 - 0.80 wt % Mn, 0.20 --- 0.80 wt. % Mg, 0.50 - 3.50 wt, % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0,15 wt. % of impurities, and the remainder AL
[00133] Illustration 2: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.20 - 1.20 wt. % Si, 0.20- 0,90 wt. % Fe, 0.0.1 - 0.30 wt. % Cu, 0.05 - 0,70 wt, % Mn, 0.20 - 0.80 wt. % Mg, 0.50 - 3.25 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. [00134] Illustration 3: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.30 - 1.10 wt. % Si, 0.30 -- 0.90 wt. % Fe, 0.01 - 0.25 wt. % Cu, 0.10 - 0.70 wt. % Mn, 0.20 - 0.80 wt. % Mg, 0.60 - 3.00 wt. % Zn, up to 0.15 wt. % Cr, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. [00135] Illustration 4: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.50 1.00 wt. % Si, 0.40 - 0.90 wt. % Fe, 0.01 - 0,30 wt. % Cu, 0.20 - 0.80 wt, % Mn, 0.20 - 0.80 wt. % Mg, 0.70 - 2.75 wt. % Zn, up to 0.10 wt. % Cr. up to 0.10 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
[00136] Illustration 5: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 0.60 - 1.00 wt. % Si, 0.70 - 1.00 wt. % Fe, 0.01 - 0.30 wt. % Cu, 0.30 - 0.70 wt, % Mn, 0,30 - 0.80 wt. % Mg, 1.00 - 2.50 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al. [00137] Illustration 6: The il lustration of any preceding or subsequent ill ustration, wherein the aluminum alloy comprises a combined content of Si and Fe from 0.50 wt. % to 2.30 wt. %.
[00138] Illustration 7: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 0.90: 1.
[00139] Illustration 8: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a combined content of Si and Fe of at least 1.30 wt. %, and wherein the aluminum alloy comprises a ratio of (Si + Fe):Mnof at least 2:1.
[00140] Illustration 9: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 10 % more alpha phase particles than AA3105 aluminum alloy.
[00141] Illustration 10: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy is a 3xxx series aluminum alloy.
[00142] Illustration 11: The illustration of any preceding or subsequent illustration, wherein an ultimate tensile strength of the aluminum alloy is at least 110 MPa.
[00143] Illustration 12: The illustration of any preceding or subsequent illustration, wherein a yield strength of the aluminum alloy is at least 50 MPa.
[00144] Illustration 13: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a conductivity from 40 % to 60 % based on the international annealed copper standard (IACS).
[00145] Illustration 14: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a corrosion potential from -740 mV to -820 mV. .00146] Illustration 15: A fin stock comprising the aluminum alloy of any preceding or subsequent illustration.
[00147] Illustration 16: An aluminum alloy product comprising a tube and a fin, wherein the fin comprises the aluminum alloy of any preceding or subsequent illustration.
[00148] Illustration 17: A method of producing an aluminum alloy product, the method comprising: casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.10 - 1.30 wt % Si, 0.10 - 1.00 wt. % Fe, up to 0,30 wt. % Cu, 0.01 - 0.80 wt. % Mn, 0.20 - 0.80 wt, % Mg, 0.50 - 3.50 wt, % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al; homogenizing or annealing the cast aluminum alloy; hot rolling the cast, aluminum alloy to produce a hot rolled product; and cold rolling the hot rolled product to produce to an aluminum alloy product,
[00149] Illustration 18: The illustra tion of any preceding or subsequent illustration, wherein the homogenization comprises heating the cast aluminum alloy to a homogenization temperature from 400 ° C to 600 °C at a heating rate of at least 10° C/h and soaking the cast aluminum alloy at the homogenization temperature for a period of time from 5 hours to 15 hours; and wherein the annealing step comprises heating the cast aluminum alloy to an annealing temperature from 300 ° C to 500 °C at a heating rate of at least 10° C/h and soaking the cast aluminum alloy at the annealing temperature for a period of time from 1 hour to 8 hours.
[00150] Illustration 19: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2:1 and wherein the aluminum alloy product has an ultimate tensile strength of at least 1 10 MPa, a yield strength of at least 50 MPa, and a conducti vity from 40 % to 60 % based on the international annealed copper standard (IACS).
[00151] Illustration 20: A fin stock prepared by the method of claim of any preceding or subsequent illustration.
Example 1
[00152] FIG. 2 shows a graph of thermodynamic calculations of the mass fraction of alpha phase particles in an aluminum alloy as a function of the amount of Si and Fe in the aluminum alloy at different temperatures. The thermodynamic calculations were performed for aluminum alloys that include 1.25 wt. % Mn. The thermodynamic calculations show that increasing Si and Fe does not linearly increase alpha phase particles. For example, in some cases, aluminum alloys including higher Fe content reduces the amount of alpha phase particles. Specifically, Curve 1 represents an aluminum alloy including 0.70 wt. % Fe and 0.80 wt. % Si, Curve 2 represents an aluminum alloy including 2.0 wt. % Fe and 0.80 wt. % Si, and Curve 3 represents an aluminum alloy including 0,70 wt. % Fe and 0.40 wt. % Si. While higher amounts of Si increase the amount of alpha phase particle formation for each of the aluminum alloys, the amount of Fe does not directly result in increased alpha phase particle formation. In particular, the aluminum alloys represented by Curves 1 and 2 include the same amount of Si, but the aluminum alloy represented by Curve 2 has a substantially higher Fe content. The aluminum alloy represented by Curve 2 had less alpha phase particle formation than the aluminum alloy represented by Curve 1 despite having higher amounts of Fe. Therefore, a balance of Si and Fe is needed to produce the optimal amount of alpha phase particles to pull Mg out of solid solution for good electrical conductivity. It was surprisingly found that the amounts of Fe and Si in an aluminum alloy composition can be optimized to maximize the formation of alpha phase particles for improved electrical conductivity properties.
[00153] Sample aluminum alloys were tested to determine the effect of the aluminum alloy on the electrical conductivity of aluminum alloys. Sample Alloys 1-29 were prepared from various aluminum alloy compositions to demonstrate the effect of the aluminum alloy composition on the electrical conductivity, Comparative Example 1 was prepared from a AA3105 aluminum alloy in a H28 temper. Comparative Example 2 was prepared from a AA3105 aluminum alloy in a H19 temper. Comparative Example 3 was prepared front a continuous cast AA3105 aluminum alloy, and Comparative Example 4 was prepared from a AA7072 aluminum alloy. Comparative Example 4 is the baseline for aluminum alloys with good thermal conductivity properties. The aluminum alloys described herein are modified 3xxx series aluminum alloys that achieve electrical conductivity properties similar to AA7072 aluminum alloy; however, due to the composition, can include higher amounts of recycled materials, thus providing a cost-effective and recycle-friendly alternative to AA7072 aluminum alloy. Sample Alloys 1-29 and Comparatives 1-4 were lab cast. The compositions of the alumin um alloys are provided below in Table 17.
Figure imgf000047_0001
Figure imgf000048_0001
[00154] FIG.3 shows the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022), Comparative Alloys 1-3 each exhibited an electrical conductivity less than 40 % IACS, whereas Sample Alloys 6, 10, 1 , 21, 19, 26, 27, 22, 29, 17, 20, 24, 11, 14, 28, 9, 15, 13, and each exhibited an electrical conductivity greater than 45 % IACS. For example, some sample aluminum alloys had greater than a 50 % increase in electrically conductivity compared to Comparative Examples 1-3. The data demonstrates that modifying the composition of a 3xxx series aluminum alloy (e.g., AA3105 aluminum alloy) can substantially improve electrical conductivity properties.
[00155] FIG.4A-4C are graphs showing the effect of the Si and Fe on the electrical conductivity (% IACS) of the sample aluminum alloys as measured by ASTM E1004 (2022). Specifically, FIG.4A shows the effec t of Si and Fe content on the electrical conductivity properties of an aluminum alloy including 0.55 wt, % Mn, FIG.4B shows the effect of Si and Fe content on the electrical conductivity properties of an aluminum alloy including 0.65 wt. % Mn, and FIG, 4C shows the effect of Si and Fe content on the electrical conductivity properties of an aluminum alloy including 0.75 wt. % Mn. The data demonstrates that increasing Si and Fe does not increase alpha phase particles ~ in some cases, higher Fe reduces the amount of alpha phase particles. Therefore, a balance of Si and Fe is needed to produce the optimal amount of alpha phase particles to pull Mg out of solid solution for good electrical conductivity.
Example 2
[00156] Sample aluminum alloys were tested to determine the effect of heat treatment on the electrical conductivity of 3xxx series aluminum alloys. An AA3105 aluminum alloy hot band was provided. The AA3105 aluminum alloy hot band had an exit temperature from hot rolling of less than 300 °C. The AA3105 aluminum alloy hot band was either subjected to: Process 1: cold rolling followed by annealing at temperatures from 300 °C to 475 °C for 2 to 24 hours; or Process 2: annealing at temperatures from 300 °C to 450° C for 2 to 24 hours.
[00157] FIGS.5A and SB are graphs of the electrical conductivity (% IACS) as measured by ASTM E1004 (2022) of an AA3105 ahtminum alloy hot band produced by Process 1 and 2 at various annealing temperatures for different periods of time. The dashed line represents AA3105 aluminum alloy hot band that was subjected to Process I (cold rolling and annealing) and the solid line represents AA3105 aluminum alloy hot band that was subjected to Process 2 (annealing). The electrical conductivity of the AA3105 aluminum alloy hot band without heat treatment (not plotted) after 24 hours was 37 % IACS. FIGS.5 A and 5B show that annealing after hot rolling or cold rolling improved electrical conductivity compared to the AA3105 aluminum alloy hot band without heat treatment. For example, the AA3105 aluminum alloy hot band that was subjected to Process 1 or Process 2 each demonstrated an electrical conductivity greater than 39 % IACS when heated for 2 hours at an annealing temperature of 300 °C or greater. Thus, the electrical conductivity for the AA3105 aluminum alloy hot band increased substantially after annealing. Additionally, at some annealing temperature ranges, cold rolling followed by annealing also improved electrical conductivity, Therefore. the data demonstrates that heat treating a AA3105 aluminum alloy hot band will increase the amount of alpha phase particles and improve electrical conductivity.
[00158] FIG. 6 shows a graph of the electrical conductivity of the sample aluminum alloys in Table 17 after heat treatment. The sample aluminum alloys were annealed at a temperat ure of 375 °C for four hours. Eac h of the sample al uminum alloys demonstrate some improvement in electrically conductivity after heat treatment. In particular, heat treatment for Sample Alloys 8, 9, 16, 19, 20, and 28 showed synergistic improvements in electrical conductivity. It is contemplated that the aluminum alloy composition in tandem with the heat treatment can synergistically increase the amount of alpha phase particles and improve electrical conductivity.
Example 3
[00159] Sample 3xxx series aluminum alloys were tested to determine the effect of Zn on the galvanic corrosion potential. The compositions of the aluminum alloys are provided below in Table 18.
Figure imgf000050_0001
[00160] FIG. 7 is a graph of the measured electrical potential difference (AEoc (mV)) of Alloys 30-33 according to ASTM G71 (2023) as a function of the Zn content. As shown in FIG. 7, the measured electrical potential difference for a 3xxx series aluminum alloy increases as a function of the Zn content in the alloy. For example, at a Zn concentration greater than 1.50 wt %, a 3xxx series aluminum alloy has an electrical potential difference of about 100 mV, which is comparable to benchmark AA7072 aluminum alloy.
[00161] All patents, publications and abstracts cited above are incorporated herein by reference in their entireties. Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptions thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

WHAT IS CLAIMED IS:
1. An aluminum alloy comprising 0.40 - 1.30 wt. % Si, 0.50 - 2.50 wt. % Fe, 0.10 - 0.40 wt, % Cu, up to 1 ,00 wt % Mn, 0.40 - 0,80 wt, % Mg, up to 3,50 wt, % Zn, up to 0.20 wt. % Cr, up to 0.20 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
2. The aluminum alloy of claim 1 , comprising 0.40 - 1.30 wt % Si, 0.50 - 2.00 wt, % Fe, 0.10 - 2.00 wt % Cu, up to 1 ,00 wt. % Mn, 0.40 - 0,80 wt % Mg, 0.50 - 3,50 wt. % Zn, up to 0.20 wt, % Cr, up to 0.20 wt. % Ti , up to 0.15 wt. % of impurities, and the remainder Al.
3. The aluminum alloy of claim 1 , comprising 0.50 - 1.20 wt. % Si, 0.60 - 1.80 wt. % Fe, 0.10 - 0,30 wt % Cu, up to 0.90 wt, % Mn, 0,40 - 0.80 wt, % Mg, up to 3,25 wt. % Zu, up to 0.15 wt. % Cr, up to 0.15 wt. % Ti, up to 0.15 wt. % of impurities, and the remainder Al .
4. The aluminum alloy of claim 1 , comprising 0.60 - 1.10 wt. % Si, 0.70 - 1.50 wt, % Fe, 0.10 - 0.30 wt. % Cu, up to 0.90 wt. % Mn, 0.50 - 0.80 wt. % Mg, up 3.00 wt. % Zn, up to 0.10 wt. % Cr, up to 0, 10 wt % Ti, up to 0.15 wt. % of impurities, and the remainder Al.
5. The aluminum alloy of claim L comprising 0.70 — 1.10 wt. % Si, 0.90 - 1 ,40 wt. % Fe, 0.15 - 0,25 wt. % Cu, up to 0,80 wt. % Mn, 0.50 -- 0.70 wt. % Mg, up to 2,75 wt. % Zn, up to 0.05 wt. % Cr, up to 0.05 wt. % Ti, up to 0.15 wt, % of impurities, and the remainder Al.
6. The aluminum alloy of claim 1 , wherein the aluminum alloy comprises a combined content of Si, Cu, and Fe from 1.00 wt. % to 4.20 wt. %.
7. The aluminum alloy of claim 1 , wherein the aluminum alloy comprises a ratio of (Si * Fe):Mn of at least 1.5:1.
8. The aluminum alloy of claim 1, wherein the aluminum alloy comprises a combined content of Si and Fe of at least 1.50 wt. %, and wherein the aluminum alloy comprises a ratio of (Si + Fe ):Mn of at least 2.0: 1.
9. The aluminum alloy of claim 1 , wherein the aluminum alloy comprises a minimum amount of 1.50 wt, % Zn.
10. The aluminum alloy of claim 1, wherein the aluminum alloy is a 3xxx series aluminum alloy.
11. The aluminum alloy of claim 1 , wherein an ultimate tensile strength of the aluminum alloy is at least 110 MPa.
12. The aluminum alloy of claim 1 , wherein a yield strength of the aluminum alloy is at least 50 MPa.
13. The aluminum alloy of claim 1 , wherein the aluminum alloy comprises a conductivity from 40 % to 60 % based on the international annealed copper standard (IACS).
14. The alumin um alloy of claim 1 wherein the aluminum alloy comprises a corrosion potential from -740 mV to -820 mV.
15. A fin stock comprising the aluminum alloy of claim 1.
16. An aluminum alloy product comprising a tube and a fin, wherein the fin comprises the fin stock according to claim 15.
17. A method of producing an aluminum alloy product, comprising: casting an aluminum alloy to form a cast aluminum alloy, wherein the aluminum alloy comprises 0.40 - 1.30 wt. % Si, 0.50 - 2.50 wt. % Fe, 0.10 - 0.40 wt. % Cu, up to 1.00 wt. % Mn, 0.40 - 0.80 wt. % Mg, up to 3.50 wt. % Zn, up to 0.20 wt. % Cr, up to 0.20 wt % Ti, up to 0.15 wt. % of impurities, and the remainder Al: homogenizing or annealing the cast aluminum alloy; hot rolling the cast aluminum alloy to produce a hot rolled product; and cold rolling the hot rolled product to produce to an aluminum alloy product.
18. The method of claim 17, wherein the homogenization comprises heating the cast aluminum alloy to a homogenization temperature from 400° C to 600 °C at a heating rate of at least 10° C/h and soaking the cast aluminum alloy at the homogenization temperature for a period of time from 5 hours to 15 hours; and wherein the annealing step comprises heating the east aluminum alloy to an annealing temperature from 300 ° C to 500 °C at a heating rate of at least 10° C/h and soaking the cast aluminum alloy at the annealing temperature for a period of time from 1 hour to 8 hours.
19. The method of claim 17, wherein the aluminum alloy comprises a ratio of (Si + Fe):Mn of at least 2: 1 and wherein the aluminum alloy product has an ultimate tensile strength of at least 110 MPa, a yield strength of at least 50 MPa, and a conductivity from 40 % to 60 % based on the international annealed copper standard (IACS).
20. A fin stock prepared by the method of claim 17.
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Citations (3)

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Publication number Priority date Publication date Assignee Title
JPH04154931A (en) * 1990-10-15 1992-05-27 Sumitomo Light Metal Ind Ltd Aluminum alloy for fin material in heat exchanger
JPH09256095A (en) * 1996-03-22 1997-09-30 Furukawa Electric Co Ltd:The Aluminum alloy sheet excellent in formability and its production
CN101186986A (en) * 2007-11-30 2008-05-28 苏州有色金属研究院有限公司 High-intensity aluminum manganese alloy for heat exchanger and its manufacture method

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Publication number Priority date Publication date Assignee Title
JPH04154931A (en) * 1990-10-15 1992-05-27 Sumitomo Light Metal Ind Ltd Aluminum alloy for fin material in heat exchanger
JPH09256095A (en) * 1996-03-22 1997-09-30 Furukawa Electric Co Ltd:The Aluminum alloy sheet excellent in formability and its production
CN101186986A (en) * 2007-11-30 2008-05-28 苏州有色金属研究院有限公司 High-intensity aluminum manganese alloy for heat exchanger and its manufacture method

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Title
ARNOLDT AUREL RAMON ET AL: "Influence of different homogenization heat treatments on the microstructure and hot flow stress of the aluminum alloy AA6082", MATERIALS CHARACTERIZATION, ELSEVIER, NEW YORK, NY, US, vol. 191, 18 July 2022 (2022-07-18), XP087145448, ISSN: 1044-5803, [retrieved on 20220718], DOI: 10.1016/J.MATCHAR.2022.112129 *

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