Note: Descriptions are shown in the official language in which they were submitted.
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
IMPROVED ROO( ALUMINUM ALLOYS, AND METHODS FOR PRODUCING THE
SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[001] This patent application claims priority to U.S. Provisional Patent
Application No.
61/408,269, entitled "IMPROVED 5XXX ALUMINUM ALLOYS, AND METHODS FOR
PRODUCING THE SAME", filed October 31, 2010, and U.S. Provisional Patent
Application
No. 61/435,543, entitled "IMPROVED 5XXX ALUMINUM ALLOYS, AND METHODS
FOR PRODUCING THE SAME", filed January 24, 2011. Each of the above-identified
patent
applications is incorporated herein by reference in its entirety.
BACKGROUND
[002] Aluminum alloys are useful in a variety of applications. However,
improving one
property of an aluminum alloy without degrading another property often proves
elusive.
SUMMARY OF THE DISCLOSURE
[003] Broadly, the present patent application relates to new 5xxx aluminum
alloy
products having an improved combination of properties. 5xxx aluminum alloys
are aluminum
alloys having magnesium as the predominate alloying ingredient, other than
aluminum, and
containing silicon as an impurity. " The new 5xxx aluminum alloy products are
made from
aluminum alloys containing 0.50 to 3.25 wt. % Mg, 0.05 to 0.20 wt. % Sc and/or
0.05 to 0.20
wt. % Zr, up to 0.50 wt. % in total of Cu and Ag, less than 0.10 wt. % Mn, up
to 0.30 wt. % in
total of Cr, V and Ti, up to 0.50 wt. % in total of Ni and Co, up to 0.25 wt.
% Fe, up to 0.25 wt.
% Si, up to 0.50 wt. % Zn, and up to 0.10 wt. % of any other element, with the
total of these
other elements not exceeding 0.35 wt. %, the balance being aluminum. The new
5xxx
aluminum alloys may comprise, consist essentially of, or consist of the stated
ingredients. The
new 5xxx aluminum alloys may realize an improved combination of properties,
such as an
improved combination of two or more of electrical conductivity, strength,
strength retention,
and intragranular corrosion resistance, among others, as shown by the below
examples. The
new 5xxx aluminum alloys may be used in high strength electrical conductor
products, among
others.
[004] The new 5xxx aluminum alloy products may realize high electrical
conductivity. In
one embodiment, a new 5xxx aluminum alloy product realizes an electrical
conductivity of at
least 35% IACS. In other embodiments, a new 5xxx aluminum alloy product
realizes an
electrical conductivity of at least 36%, or at least 37%, or at least 37.5%,
or at least 38%, or at
Page 1 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
least 39%, or at least 40%, or at least 41%, or at least 42%, or at least
42.5%, or at least 43%,
or at least 44%, or at least 45%, or at least 46%, or at least 47%, or at
least 47.5%, or at least
48%, or at least 49%, or at least 50%, or at least 51%, or at least 52%, or at
least 53%, or at
least 54%, or at least 55% IACS, or higher. These properties are measured
after the new 5xxx
aluminum alloy product has been stabilized, i.e., annealed at 250 F for 6
hours.
[005] The new 5xxx aluminum alloy products may realize high strength. In
one
embodiment, a new 5xxx aluminum alloy product realizes a longitudinal (L)
tensile yield
strength (TYS) of at least 270 MPa. In other embodiments, a new 5xxx aluminum
alloy
product realizes a longitudinal tensile yield strength of at least 280 MPa, or
at least 290 MPa,
or at least 300 MPa, or at least 310 MPa, or at least 320 MPa, or at least 330
MPa, or at least
340 MPa, or at least 350 MPa, or at least 360 MPa, or at least 370 MPa, or at
least 380 MPa, or
at least 390 MPa, or at least 400 MPa, or higher. These properties are
measured after the new
5xxx aluminum alloy has been stabilized, i.e., annealed at 250 F for 6 hours.
[006] The new 5xxx aluminum alloy products may realize high retained
strength. For
example, a thermally exposed version of the new 5xxx aluminum alloy product
(e.g., exposed
to temperatures of 250 F-500 F, or higher, for 100 hours +/- 0.5 hour) may
retain at least 70%
of its longitudinal tensile yield strength relative to the longitudinal
tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy product. A non-
thermally
exposed version of the same 5xxx aluminum alloy product is the product as
annealed at 250 F
for 6 hours (i.e., the stabilized baseline product). A piece of the non-
thermally exposed version
of the 5xxx aluminum alloy product is then exposed to elevated temperature for
an additional
100 hours +/- 0.5 hour to obtain the thermally, exposed version of the new
5xxx aluminum
alloy product. To determine strength retention, strength properties of both
the non-thermally
exposed and the thermally exposed products are measured at room temperature,
and in
accordance with ASTM E8 and B557. See, Example 4, below.
[007] Strength retention may be measured relative to the longitudinal
tensile yield
strength, the long-transverse tensile yield strength and/or the short-
transverse yield strength of
the aluminum alloy. In one embodiment, strength retention is measured relative
to longitudinal
tensile yield strength. Those skilled in the art recognize that different
combinations of
temperatures and/or exposure periods may yield varying results.
[008] In one approach, the thermally exposed version is exposed to a
temperature of
260 F for 100 hours +/- 0.5 hour. In this approach, the thermally exposed
version may realize
Page 2 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
a retained longitudinal tensile yield strength of at least 95% relative to the
longitudinal tensile
yield strength of a non-thermally exposed version of the same 5xxx aluminum
alloy product.
In one embodiment, the thermally exposed version may realize a retained
strength of at least
96% relative to the non-thermally exposed version of the same 5xxx aluminum
alloy product.
In other embodiments, the thermally exposed version may realize a retained
strength of at least
97%, such as at least 98%, or at least 99%, or at least 100% relative to the
non-thermally
exposed version of the same 5xxx aluminum alloy product. In some embodiments,
the
thermally exposed version of the new 5xxx aluminum alloy product has a higher
strength than
the non-thermally exposed version of the same 5xxx aluminum alloy product,
such as at least
about 1% or 2% higher strength, i.e., a retained strength of at least 101%, or
at least 102%.
See, Example 4, below.
[009] In another approach, the thermally exposed version is exposed to a
temperature of
300 F for 100 hours +/- 0.5 hour. In this approach, the thermally exposed
version may realize
a retained longitudinal tensile yield strength of at least 93% relative to the
longitudinal tensile
yield strength of a non-thermally exposed version of the same 5xxx aluminum
alloy product.
In one embodiment, the thermally exposed version may realize a retained
strength of at least
94% relative to the non-thermally exposed version of the same 5xxx aluminum
alloy product.
In other embodiments, the thermally exposed version may realize a retained
strength of at least
95%, such as at least 96%, or at least 97%, or at least 98% relative to the
non-thermally
exposed version of the same 5xxx aluminum alloy product.
[0010] In yet another approach, the thermally exposed version is exposed to
a temperature
of 350 F for 100 hours +/- 0.5 hour. In this approach, the thermally exposed
version may
realize a retained longitudinal tensile yield strength of at least 84%
relative to the longitudinal
tensile yield strength of a non-thermally exposed version of the same 5xxx
aluminum alloy
product. In one embodiment, the thermally exposed version may realize a
retained strength of
at least 85% relative to the non-thermally exposed version of the same 5xxx
aluminum alloy
product. In other embodiments, the thermally exposed version may realize a
retained strength
of at least 86%, such as at least 87%, or at least 88%, or at least 89%, or at
least 90%, or at
least 91% relative to the non-thermally exposed version of the same 5xxx
aluminum alloy
product.
[0011] In yet another approach, the thermally exposed version is exposed to
a temperature
of 400 F for 100 hours +/- 0.5 hour. In this approach, the thermally exposed
version may
Page 3 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
realize a retained longitudinal tensile yield strength of at least 75%
relative to the longitudinal
tensile yield strength of a non-thermally exposed version of the same 5xxx
aluminum alloy
product. In one embodiment, the thermally exposed version may realize a
retained strength of
at least 80% relative to the non-thermally exposed version of the same 5xxx
aluminum alloy
product. In other embodiments, the thermally exposed version may realize a
retained strength
of at least 82%, such as at least 84%, or at least 86%, or at least 88%
relative to the non-
thermally exposed version of the same 5xxx aluminum alloy product.
[0012] In yet another approach, the thermally exposed version is exposed to
a temperature
of 450 F for 100 hours +/- 0.5 hour. In this approach, the thermally exposed
version may
realize a retained longitudinal tensile yield strength of at least 70%
relative to the longitudinal
tensile yield strength of a non-thermally exposed version of the same 5xxx
aluminum alloy
product. In one embodiment, the thermally exposed version may realize a
retained strength of
at least 75% relative to the non-thermally exposed version of the same 5xxx
aluminum alloy
product. In other embodiments, the thermally exposed version may realize a
retained strength
of at least 80%, such as at least 82%, or at least 84%, or at least 86%
relative to the non-
thermally exposed version of the same 5xxx aluminum alloy product.
[0013] In yet another approach, the thermally exposed version is exposed to
a temperature
of 500 F for 100 hours +/- 0.5 hour. In this approach, the thermally exposed
version may
realize a retained longitudinal tensile yield strength of at least 70%
relative to the longitudinal
tensile yield strength of a non-thermally exposed version of the same 5xxx
aluminum alloy
product. In one embodiment, the thermally exposed version may realize a
retained strength of
at least 75% relative to the non-thermally exposed version of the same 5xxx
aluminum alloy
product. In other embodiments, the thermally exposed version may realize a
retained strength
of at least 80%, such as at least 82%, or at least 84%, or at least 85%
relative to the non-
thermally exposed version of the same 5xxx aluminum alloy product.
[0014] The new 5xxx aluminum alloy products may realize low intragranular
corrosion. In
one embodiment, a new 5xxx aluminum alloy product realizes a mass loss of not
greater than
15 mg/cm2 when tested in accordance with ASTM G67. To test corrosion
resistance, the new
5xxx aluminum alloy product is annealed at 250 F for 6 hours, and is then
sensitized by
exposing to a temperature of 100 C (212 F) for 1 week. See, Example 1, below.
In other
embodiments, a new 5xxx aluminum alloy product realizes a mass loss of not
greater than 14
mg/cm2, or not greater than 13 mg/cm2, or not greater than 12 mg/cm2, or not
greater than 11
Page 4 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
mg/cm2, or not greater than 10 mg/cm2, or not greater than 9 mg/cm2, or not
greater than 8
mg/cm2, or not greater than 7 mg/cm2, or not greater than 6 mg/cm2, or not
greater than 5
mg/cm2, or less mass loss.
[0015] The new 5xxx aluminum alloys generally include from 0.5 wt. % to
3.25 wt. % Mg.
In one embodiment, the new 5xxx aluminum alloys include at least 0.80 wt. %
Mg. In one
embodiment, the new 5xxx aluminum alloys include not greater than 2.90 wt. %
Mg. The
amount of magnesium used in the alloy may be related to the strength,
electrical conductivity,
and/or corrosion resistance properties of the alloy. High electrical
conductivity and better
corrosion resistance occurs with lower levels of magnesium. Higher strength
occurs with
higher levels of magnesium. See Tables I-A to I-C, below, for various
magnesium ranges
relative to various electrical conductivity properties.
[0016] The new 5xxx aluminum alloys may include both scandium (Sc) and
zirconium
(Zr), and generally from 0.05 to 0.20 wt. % each of Sc and Zr. The combination
of scandium
and zirconium may contribute to increased strength. In one embodiment, the new
5xxx
aluminum alloys include from 0.07 to 0.18 wt. % each of Sc and Zr. However, in
other
embodiments, only one of scandium or zirconium may be used, and in the above
amounts, such
as in lower strength applications.
[0017] The new 5xxx aluminum alloys may optionally include copper (Cu)
and/or silver
(Ag). Copper and/or silver may improve strength. However, too much copper may
decrease
corrosion resistance. In one approach, the new 5xxx aluminum alloys include up
to 0.50 wt. %
Cu, and silver is absent from the alloy (i.e., the alloy contains silver as an
"other element",
defined below). In one embodiment of this approach, the new 5xxx aluminum
alloys include
0.05 to 0.50 wt. % Cu. In another embodiment of this approach, the new 5xxx
aluminum
alloys include 0.10 to 0.45 wt. % Cu. In yet another embodiment of this
approach, the new
5xxx aluminum alloys include 0.20 to 0.40 wt. % Cu. In yet another embodiment
of this
approach, the new 5xxx aluminum alloys include 0.25 to 0.35 wt. % Cu.
[0018] In another approach, the new 5xxx aluminum alloys include up to 0.50
wt. % Ag,
and copper is absent from the alloy (i.e., the alloy contains copper as an
"other element",
defined below). In one embodiment of this approach, the new 5xxx aluminum
alloys include
0.05 to 0.50 wt. % Ag. In another embodiment of this approach, the new 5xxx
aluminum
alloys include 0.10 to 0.45 wt. % Ag. In yet another embodiment of this
approach, the new
Page 5 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
5xxx aluminum alloys include 0.20 to 0.40 wt. % Ag. In yet another embodiment
of this
approach, the new 5xxx aluminum alloys include 0.25 to 0.35 wt. % Ag.
[0019] In yet another approach, the new 5xxx aluminum alloys include both
Cu+Ag and up
to 0.50 wt. % Ag. In one embodiment of this approach, the new 5xxx aluminum
alloys include
0.05 to 0.50 wt. % total of Cu+Ag. In another embodiment of this approach, the
new 5xxx
aluminum alloys include 0.10 to 0.45 wt. % total of Cu+Ag. In yet another
embodiment of this
approach, the new 5xxx aluminum alloys include 0.20 to 0.40 wt. % total of
Cu+Ag. In yet
another embodiment of this approach, the new 5xxx aluminum alloys include 0.25
to 0.35 wt.
% total of Cu+Ag.
[0020] The new 5xxx aluminum alloys should include low amounts of manganese
(Mn).
Manganese detrimentally impacts electrical conductivity. In one embodiment,
the new 5xxx
aluminum alloys include less than 0.10 wt. % Mn. In another embodiment, the
new 5xxx
aluminum alloys include not greater than 0.07 wt. % Mn. In yet another
embodiment, the new
5xxx aluminum alloys include not greater than 0.05 wt. % Mn. In yet another
embodiment, the
new 5xxx aluminum alloys include not greater than 0.03 wt. % Mn. In yet
another
embodiment, the new 5xxx aluminum alloys include not greater than 0.01 wt. %
Mn.
[0021] The new 5xxx aluminum alloys should restrict the amount of chromium
(Cr),
vanadium (V), and titanium (Ti). These elements may detrimentally impact
electrical
conductivity. In one embodiment, the new 5xxx aluminum alloys include not
greater than 0.30
wt. % total of Cr, V and Ti (i.e., the total combined amounts of Cr, V, and Ti
does not exceed
0.30 wt. %). In one embodiment, the new 5xxx aluminum alloys include not
greater than 0.25
wt. % total of Cr, V and Ti. In yet another embodiment, the new 5xxx aluminum
alloys
include not greater than 0.20 wt. % total of Cr, V and Ti. In yet another
embodiment, the new
5xxx aluminum alloys include not greater than 0.15 wt. % total of Cr, V and
Ti. In yet another
embodiment, the new 5xxx aluminum alloys include not greater than 0.10 wt. %
total of Cr, V
and Ti. In yet another embodiment, the new 5xxx aluminum alloys include not
greater than
0.05 wt. % total of Cr, V and Ti. In yet another embodiment, the new 5xxx
aluminum alloys
include not greater than 0.03 wt. % total of Cr, V and Ti. In any of these
embodiments, the
new 5xxx aluminum alloy may include at least 0.005 wt. % Ti (e.g., for grain
refining
purposes).
[0022] The new 5xxx aluminum alloys should restrict the amount of nickel
(Ni) and cobalt
(Co). These elements may detrimentally impact electrical conductivity. In one
embodiment,
Page 6 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
the new 5xxx aluminum alloys include not greater than 0.50 wt. % total of Ni
and Co (i.e., the
total combined amounts of Ni and Co does not exceed 0.50 wt. %). In one
embodiment, the
new 5xxx aluminum alloys include not greater than 0.35 wt. % total of Ni and
Co. In another
embodiment, the new 5xxx aluminum alloys include not greater than 0.20 wt. %
total of Ni and
Co. In yet another embodiment, the new 5xxx aluminum alloys include not
greater than 0.15
wt. % total of Ni and Co. In yet another embodiment, the new 5xxx aluminum
alloys include
not greater than 0.10 wt. % total of Ni and Co. In yet another embodiment, the
new 5xxx
aluminum alloys include not greater than 0.05 wt. % total of Ni and Co. In yet
another
embodiment, the new 5xxx aluminum alloys include not greater than 0.03 wt. %
total of Ni and
Co. In yet another embodiment, the new 5xxx aluminum alloys include not
greater than 0.01
wt. % total of Ni and Co.
[0023] The new 5xxx aluminum alloys should restrict the amount of iron
(Fe), silicon (Si)
and zinc (Zn) impurities. Iron and silicon impurities may detrimentally impact
strength. In
one embodiment, the new 5xxx aluminum alloys include not greater than 0.25 wt.
% each of
Fe and Si. In another embodiment, the new 5xxx aluminum alloys include not
greater than
0.20 wt. % Fe and not greater than 0.15 wt. % Si. In yet another embodiment,
the new 5xxx
aluminum alloys include not greater than 0.15 wt. % Fe and not greater than
0.10 wt. % Si. In
yet another embodiment, the new 5xxx aluminum alloys include not greater than
0.10 wt. % Fe
and not greater than 0.05 wt. % Si. Zinc impurities may detrimentally affect
corrosion
resistance. In one embodiment, the new 5xxx aluminum alloys include not
greater than 0.50
wt. % Zn. In another embodiment, the new 5xxx aluminum alloys include not
greater than
0.35 wt. % Zn. In yet another embodiment, the new 5xxx aluminum alloys include
not greater
than 0.25 wt. % Zn.
[0024] The new 5xxx aluminum alloys may be substantially free of other
elements (e.g.,
casting aids and other impurities, i.e., other than the iron, silicon and zinc
impurities described
above). As used herein, "other elements" means any other elements of the
periodic table other
than the above-listed magnesium, scandium, zirconium, copper and/or silver (as
applicable -
see above), manganese, chromium, vanadium, titanium, nickel, cobalt, iron,
silicon, and zinc,
described above. In the context of this paragraph the phrase "substantially
free" means that the
new 5xxx aluminum alloys contain not more than 0.10 wt. % each of any other
element, with'
the total combined amount of these other elements not exceeding 0.35 wt. % in
the new 5xxx
aluminum alloy. In another embodiment, each one of these other elements,
individually, does
Page 7 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
not exceed 0.05 wt. % in the 5xxx aluminum alloy, and the total combined
amount of these
other elements does not exceed 0.15 wt. % in the 5xxx aluminum alloy. In
another
embodiment, each one of these other elements, individually, does not exceed
0.03 wt. % in the
5xxx aluminum alloy, and the total combined amount of these other elements
does not exceed
0.10 wt. % in the 5xxx aluminum alloy.
[0025] Examples of various types of new 5xxx aluminum alloy compositions
are provided
in Tables I-A to I-C, below. Embodiments of properties that may be achieved by
the new 5xxx
aluminum alloys when rolled to a thickness of about 1.0 - 1.1 mm, and annealed
at a
temperature of 250 F for a period of 6 hours are provided in Table I-D, below.
Table I-A - Non-Limiting examples of compositions of new 5xxx aluminum alloys
for
achieving an electrical conductivity of 35.0 to 39.9 % IACS
Elect. Cond. Broad Composition Preferred More Preferred
(% IACS) Composition Composition
2.70 - 3.25 wt. % Mg; 2.70 - 3.25 wt. % Mg; 2.70 - 3.25 wt. %
Mg;
0.05 - 0.20 wt. % Sc; 0.07 - 0.18 wt. % Sc; 0.07 - 0.18 wt. %
Sc;
and/or and and
0.05 - 0.20 wt. % Zr; 0.07 - 0.18 wt. % Zr; 0.07 - 0.18 wt. %
Zr;
< 0.50 wt. % Cu+Ag; 0.05 - 0.50 wt. % 0.10 - 0.45 wt. %
<0.10 wt. % Mn; Cu+Ag; Cu+Ag;
< 0.50 wt. % Ni + Co; < 0.05 wt. % Mn; < 0.03 wt. % Mn;
<
35 0 39.9
0.30 wt. % Cr + V + < 0.25 wt. % Ni + Co; < 0.05 wt. % Ni +
Co;
-.
Ti; <0.15 wt.%Cr+V+ <0.05 wt.%Cr+V+
<0.50 wt. % Zn; Ti; Ti;
< 0.25 wt. % Fe; < 0.35 wt. % Zn; < 0.25 wt. % Zn;
< 0.25 wt. % Si; < 0.15 wt. % Fe; < 0.10 wt. % Fe;
< 0.10 wt. % other < 0.10 wt. % Si; < 0.05 wt. % Si;
elefnents; < 0.05 wt. % other < 0.03 wt. % other
<0.35 wt. % of the elements; elements;
other elements; < 0.15 wt. % of the < 0.10 wt. % of the
balance aluminum other elements; other elements;
balance aluminum balance aluminum
Table I-B - Non-Limiting examples of compositions of new 5xxx aluminum alloys
for
achieving an electrical conductivity of 40.0 to 44.9 % IACS
Elect. Cond. Broad Composition Preferred More Preferred
(% IACS) Composition Composition
40.0 - 44.9 1.85 -2.70 wt. % Mg; 1.85 -2.70 wt. % Mg;
1.85 -2.70 wt. % Mg;
Page 8 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Elect. Cond. Broad Composition Preferred More Preferred
(% IACS) Composition Composition
0.05 - 0.20 wt. % Sc; 0.07 - 0.18 wt. % Sc; 0.07 - 0.18 wt. %
Sc;
and/or and and
0.05 - 0.20 wt. % Zr; 0.07 - 0.18 wt. % Zr; 0.07 - 0.18 wt. %
Zr;
< 0.50 wt. % Cu+Ag; 0.05 - 0.50 wt. % 0.10 - 0.45 wt. %
< 0.07 wt. % Mn; Cu+Ag; Cu+Ag;
< 0.20 wt. % Ni + Co; < 0.05 wt. % Mn; < 0.03 wt. % Mn;
< 0.10 wt. % Cr + V + < 0.10 wt. %Ni + Co; < 0.05 wt. %Ni + Co;
Ti; <0.07 wt.%Cr+V+ <0.05 wt.%Cr+V+
< 0.50 wt. % Zn; Ti; Ti;
< 0.25 wt. % Fe; < 0.35 wt. % Zn; < 0.25 wt. % Zn;
< 0.25 wt. % Si; < 0.15 wt. % Fe; < 0.10 wt. % Fe;
< 0.10 wt. % other < 0.10 wt. % Si; < 0.05 wt. % Si;
elements; < 0.05 wt. % other < 0.03 wt. % other
< 0.35 wt. % of the elements; elements;
other elements; < 0.15 wt. % of the < 0.10 wt. % of the
balance aluminum other elements; other elements;
balance aluminum balance aluminum .
Table I-C - Non-Limiting examples of compositions of new 5xxx aluminum alloys
for
achieving an electrical conductivity of at least 45.0 % IACS
Elect. Cond. Broad Composition Preferred More Preferred
(% IACS) Composition Composition
0.50 - 1.85 wt. % Mg; 0.50 - 1.85 wt. % Mg; 0.50 - 1.85 wt. %
Mg;
0.05 -0.20 wt. % Sc; 0.07 - 0.18 wt. % Sc; 0.07 - 0.18 wt. %
Sc;
and/or and and
0.05 -0.20 wt. % Zr; 0.07 - 0.18 wt. % Zr; 0.07 - 0.18 wt. %
Zr;
< 0.50 wt. % Cu+Ag; 0.05 - 0.50 wt. % 0.10 - 0.45 wt. %
< 0.05 wt. % Mn; Cu+Ag; Cu+Ag;
<0.05 wt. % Ni + Co; < 0.03 wt. % Mn; < 0.01 wt. % Mn;
<
>45 0 0.07 wt. % Cr + V + < 0.03 wt. % Ni + Co; <0.01 wt. % Ni +
Co;
.
Ti; <0.05 wt.%Cr+V+ <0.03 wt.%Cr+V+
< 0.50 wt. % Zn; Ti; Ti;
< 0.25 wt. % Fe; < 0.35 wt. % Zn; < 0.25 wt. % Zn;
< 0.25 wt. % Si; <0.15 wt. % Fe; < 0.10 wt. % Fe;
< 0.10 wt. % other < 0.10 wt. % Si; < 0.05 wt. % Si;
elements; < 0.10 wt. % other < 0.05 wt. % other
<0.35 wt. % of the elements; elements;
other elements; < 0.35 wt. % of the < 0.15 wt. % of the
balance aluminum other elements; other elements;
balance aluminum balance aluminum
Page 9 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Table I-D - Non-Limiting Embodiments of property boundaries of new 5xxx
aluminum alloys
(see, FIG. 15c)
Elec. Conduct. TYS (L)
Intercept
Embodiment Bounding line
(% IACS) (M[Pa) ant.)
1 > 35% > 270 IACS > -0.195(TYS)
+ Int. 96
2 >35% ?270 IACS > -0.195(TYS) + Int. 100
3 > 35% > 270 IACS > -0.195(TYS)
+ Int. 102
4 ?35% >270 IACS > -0.195(TYS) + Int. 104
> 35% > 270 IACS > -0.195(TYS) + Int.
106
6 > 35% 2270 IACS > -0.195(TYS) + Int.. 108
7 >35% >270 IACS > -0.195(TYS) + Int. 110
,
. _______________________________________________________________________ ,
9 235% 2290 IACS? -0.195(TYS) + Int. 96
235% 2290 IACS > -0.195(TYS) + Int. 100
11 235% 2290 IACS > -0.195(TYS) + Int. 102
12 >35% 2290 IACS > -0.195(TYS) + Int. 104
13 235% 2290 IACS > -0.195(TYS) + Int. 106
14 235% 2290 IACS > -0.195(TYS) + Int. 108
> 35% 2290 IACS > -0.195(TYS) + Int.
110
1
5 . .
16 > 35% > 310 IACS > -0.195(TYS) +
Int. 96
17 > 35% > 310 IACS > -0.195(TYS) +
Int. 100
18 > 35% > 310 IACS > -0.195(TYS) +
Int. 102
19 > 35% > 310 IACS? -0.195(TYS) +
Int. 104
> 35% > 310 IACS? -0.195(TYS) + Int.
106
21 235% 2310 IACS > -0.195(TYS) + Int. 108
22 > 35% >:310 IACS > -0.195(TYS) +
Int. 110
-IIIIIIIIIIIII-' 1
23 235% 2330 IACS > -0.195(TYS) + Int. 100
24 235% 2330 IACS > -0.195(TYS) + Int. 102
235% 2330 IACS > -0.195(TYS) + Int. 104
26 > 35% 2330 IACS > -0.195(TYS) + Int. 106
27 > 35% 2330 IACS > -0.195(TYS) + Int. 108
28 235% 2330 IACS > -0.195(TYS) +
Int. 110
,
29 > 35% > 350 IACS > -0.195(TYS) +
Int. 104
> 35% > 350 IACS > -0.195(TYS) + Int.
106
31 235% 2350 IACS > -0.195(TYS) + Int. 108
32 235% 2350 IACS > -0.195(TYS) + Int. 110
_________ 111 . 1 ________ M _________________________________ _ M_
_ill_ 112
33 237.5% > 270 IACS > -0.195(TYS) +
Int. __ 96
34 > 37.5% > 270 IACS > -0.195(TYS) +
Int. 100
237.5% 2270 IACS > -0.195(TYS) + Int. 102
36 237.5% 2270 IACS > -0.195(TYS) + Int. 104
37 237.5% 2270 IACS > -0.195(TYS) + Int. 106
38 237.5% 2270 IACS > -0.195(TYS) + Int. 108
Page 10 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Elec. Conduct. TYS (L) Intercept
Embodiment Bounding line
(% IACS) (MPa) (Int.)
39 >37.5% ?270 IACS > -0.195(TYS) + Int. 110
. = = __
40 > 40.0% > 270 IACS? -0.195(TYS) + Int. 96
41 > 40.0% > 270 IACS > -0.195(TYS) + Int. 100
42 > 40.0% > 270 IACS > -0.195(TYS) + Int. 102
43 > 40.0% > 270 IACS > -0.195(TYS) + Int. 104
44 240.0% 2270 IACS > -0.195(TYS) + Int. 106
45 240.0% > 270 IACS > -0.195(TYS) + Int. 108
46 240.0% 2270 IACS > -0.195(TYS) + Int. 110
47 > 42.5% > 270 IACS? -0.195(TYS) + Int. 96
48 242.5% 2270 IACS > -0.195(TYS) + Int. 100
49 242.5% 2270 IACS > -0.195(TYS) + Int. 102
50 >42.5% 2270 IACS > -0.195(TYS) + Int. 104
51 242.5% > 270 IACS > -0.195(TYS) + Int. 106
52 242.5% 2270 IACS > -0.195(TYS) + Int. 108
53 242.5% 2270 IACS > -0.195(TYS) + Int. 110
54 245.0% 2270 IACS > -0.195(TYS) + Int. 100
55 245.0% 2270 IACS > -0.195(TYS) + Int. 102
56 245.0% 2270 IACS > -0.195(TYS) + Int. 104
57 245.0% > 270 IACS > -0.195(TYS) + Int. 106
58 > 45.0% 2270 IACS > -0.195(TYS) + Int. 108
59 >45.0% >270 IACS > -0.195 TYS) + Int. 110
mom
Ell
60 247.5% 2270 IACS > -0.195(TYS) + Int. 102
61 247.5% 2270 IACS > -0.195(TYS) + Int. 104
62 > 47.5% 2270 IACS > -0.195(TYS) + Int. 106
63 247.5% 2270 IACS > -0.195(TYS) + Int. 108
64 247.5% 2270 IACS > -0.195(TYS) + Int. 110
-
65 > 50.0% > 270 IACS > -0.195(TYS) + Int.- 103
66 > 50.0% > 270 IACS > -0.195(TYS) + Int. 104
67 > 50.0% > 270 IACS > -0.195(TYS) + Int. 106
68 > 50.0% > 270 IACS > -0.195(TYS) + Int. 108
69 > 50.0% > 270 IACS > -0.195(TYS) + Int. 110
Any of the above-described examples and embodiments are within the scope of
the claimed
invention, and may be utilized in any claim to define the invention.
[0026] Generally, the new 5xxx aluminum alloys are in the form of a wrought
product.
For purposes of the present patent application, wrought products include
products made from
semi-continuous casting processes, such as ingot or billet casting processes,
as well as those
Page 11 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
products made from continuous casting processes, such as belt casting, rod
casting, twin roll
casting, twin belt casting (e.g., Hazelett casting), drag casting, and block
casting, among
others. The wrought products may be, for example, a sheet, extrusion, forging,
rod or wire,
and pipe or tube, among others. A sheet is a rolled product having a thickness
of 0.006 to
0.249 inch (0.1524 to 6.3246 mm). An extrusion is product formed by pushing
material
through a die. A forging is metal part worked to a predetermined shape by one
or more
processes such as hammering, pressing or rolling. In one embodiment, the
forging is a die
forging. A die forging is a forging formed to the required shape and size by
working
impression dies. A rod is a solid product that is long in relation to cross
section, and which is
0.375 inch (9.525 mm) or greater in diameter. A wire is a solid wrought
product that is long in
relation to its cross section, which is square or rectangular with sharp or
rounded corners or
edges, or is round, a regular hexagon or regular octagon, and whose diameter
or greatest
perpendicular distance between parallel faces (except for flattened wire) is
less than 0.375 inch
(9.525 mm). A tube is a hollow wrought product that is long in relation to its
cross section,
which is round, a regular hexagon, a regular octagon, elliptical, or square or
rectangular, with
sharp or rounded corners, and that has a uniform wall thickness except as
affected by corner
radii. A pipe is a tube in standardized combinations of outside diameter and
wall thickness,
commonly designated by "Nominal Pipe Sizes" and "ANSI Schedule Numbers." In
one
embodiment, the new 5xxx aluminum alloy product is in the form of sheet. In
another
embodiment, the new 5xxx aluminum alloy product is in the form of an
extrusion. In another
embodiment, the new 5xxx aluminum alloy product is in the form of a forging.
In another
embodiment, the new 5xxx aluminum alloy product is in the form of a die
forging. In another
embodiment, the new 5xxx aluminum alloy product is in the form of a wire. In
another
embodiment, the new 5xxx aluminum alloy product is in the form of a rod. In
another
embodiment, the new 5xxx aluminum alloy product is in the form of a tube. In
yet another
embodiment, the new 5xxx aluminum alloy product is in the form of a pipe.
[0027] To produce a new 5xxx aluminum alloy wrought product using a semi-
continuous
casting process, the new 5xxx aluminum alloy may be cast in the form of an
ingot or billet,
after which the ingot or billet is homogenized and hot worked to an
intermediate gauge
product. The intermediate gauge product may then be optionally thermally
treated (e.g.,
annealed) and then cold worked to final gauge or form. After cold working, the
product may
be annealed for a time and temperature sufficient to stabilize properties
(e.g., 6 hours at 250 F,
or similar type of anneal). Similar steps may be employed with a continuous
casting process,
Page 12 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
although hot working may not be required. In one embodiment, the new 5xxx
aluminum alloy
products are cold worked at least 10%. In other embodiments, the new 5xxx
aluminum alloy
products are cold worked at least worked at least 25%, or at least 50%, or at
least 60%, or at
least 70%, or at least 80%, or at least 90%, or more. In this regard, the new
5xxx aluminum
alloy products may be processed to an H temper, such as any of an H1, H2 or H3
temper.
[0028] An H1 temper means that the alloy is strain hardened. An H2 temper
means that
the alloy is strain-hardened and partially annealed. An H3 temper means that
the alloy is strain
hardened and stabilized (e.g., via low temperature heating). In some
embodiments, the new
5xxx aluminum alloy products may achieve an improved combination of properties
in one or
more of an H1X, H2X or an H3X temper, where X is a whole number from 1-9. This
second
digit following the designations H1, H2, H3 indicate the final degree of
strain hardening. The
number 8 is assigned to tempers having a final degree of strain-hardening
equivalent to that
resulting from approximately 75% reduction in area. Tempers between that of
the 0 Temper
(annealed) and 8 (full hard) are designated by the numbers 1 through 7. A
number 4
designation is considered half-hard; number 2 is considered quarter-hard; and
the number 6 is
three-quarter hard. When the number is odd, the limits of ultimate strength
are about halfway
between those of the even numbered tempers. An H9 temper has a minimum
ultimate tensile
strength that exceeds the ultimate tensile strength of the H8 temper by at
least 2 ksi.
[0029] Given the strength, electrical conductivity, corrosion resistance
and/or strength
retention properties of the new 5xxx aluminum alloy products, such products
are well-suited as
electrical conductors. An electrical conductor is a material whose primary
application is to
conduct electricity and that has an electrical conductivity of at least 35%
IACS, such as any of
the IACS values described above. Examples of electrical conductors include
electrical
connectors and electrical conveyors, among others. For the present patent
application, the term
"electrical conductors" does not include memory disk stock and the like, whose
primary
application is as a substrate for memory storage.
[0030] A high strength electrical conductor is an electrical conductor
having a tensile yield
strength of at least 270 MPa, such as any of the strength values described
above.
[0031] A corrosion-resistant electrical conductor is an electrical
conductor that realizes a
mass loss of not greater than 15 mg/cm2 when tested in accordance with ASTM
G67, such as
any of the mass loss values described above.
Page 13 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
[0032] A high strength retention electrical conductor is an electrical
conductor that retains
at least 70% of its longitudinal tensile yield strength after prolonged
exposure to elevated
temperature, relative to the longitudinal tensile yield strength of a non-
thermally exposed
version of the same 5xxx aluminum alloy product, as described above, and such
as any of the
strength retention values described above. In these embodiments, the
mechanical properties
may be measured at about room temperature (e.g., about 25 C), such as after
the thermal
exposure has been completed.
[0033] An electrical connector is a device configured to reliably connect
one thing to and
another thing such that the two things are in sound electrical communication
upon and during
application of an electrical current. Non-limiting examples of electrical
connectors include
terminal blocks, pins, crimp-on connectors, plug and socket connectors, blade
connectors, and
ring and spade terminals, to name a few. In one embodiment, a first electrical
connector is a
male connector and a second electrical connector is a female connector,
adapted to receive the
male connector. In some of these embodiment, the male and female electrical
connectors may
be in a keyed arrangement, where the male connector may connect with the
female connector
only when the male connector is in a predetermined configuration and/or
orientation relative to
the female connector. In one embodiment, the male and female connectors may be
reliably
and/or repeatably connected to and disconnected from one another (i.e., mated
and unmated),
and over many connect and disconnect cycles. Examples of some useful
electrical connectors
using the aluminum alloy of the present application include automotive
electrical connectors.
[0034] An automotive electrical connector is an electrical connector that
is used in an
automotive vehicle. One non-limiting example of an automotive electrical
connector is an
electrical distribution system. The automotive electrical connectors may
include the aluminum
alloys described herein, and those aluminum alloys may be corrosion resistant
and/or have high
strength retention, to name a few. Automotive electrical conductors may also
and/or
alternatively be in the form of an electrical conveyor, described below.
[0035] For purpose of the present application, an automotive vehicle means
a vehicle
designed to transport one or more passengers via locomotion using one or more
motors and/or
one or more engines. Non-limiting examples of automotive vehicles include
hydrocarbon
powered vehicles (e.g., gasoline, diesel, alcohol (e.g., ethanol), and
mixtures thereof (e.g., E85
), to name a few), electrically powered vehicles, and hybrid powered
(hydrocarbon + electric)
vehicles, among others. For example, buses, trains, cars, trucks, motorcycles,
off-road
Page 14 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
vehicles, and airplanes, among others, are all automotive vehicles. Automotive
vehicles may
travel via rail, road, water, snow, earth, air and/or otherwise.
[0036] An electrical conveyor is a device whose primary application is to
convey
electricity from one point to another point. Examples of electrical conveyers
include wires,
cables and bus bars, among others. An electrical wire is an elongated piece,
resembling a
string, and which is designed to carry electrical current from a first
location to a second
location. A cable is a device including a plurality of electrical wires,
generally in a twisted
configuration. A bus bar is a device, usually in the form of a bar, which is
designed to carry
electrical current from a first location to a second location. A bus bar may
be comprised of a
plurality of long and/or thin sheets.
[0037] The electrical conductors may be in a plated or unplated form. When
in plated
form, the electrical conductors may include the new 5xxx aluminum alloy
products with a
plated portion included on one or more surfaces of the new 5xxx aluminum alloy
products.
The plated portion may include another metal, such as tin, zinc or copper, to
name a few. The
plated portion may be coupled to the new 5xxx aluminum alloy products via any
suitable
technique, such via electroplating and/or other known deposition techniques.
[0038] These and other aspects, advantages, and novel features of this new
technology are
set forth in part in the description that follows, and will become apparent to
those skilled in the
art upon examination of the description and figures, or may be learned by
practicing one or
more embodiments of the technology provided for by the patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a graph illustrating electrical conductivity versus Mg
content for the
Example 1 alloys.
[0040] FIG. 2 is a graph illustrating Mn content versus electrical
conductivity for some
Example 1 alloys.
[0041] FIG. 3 is a graph illustrating tensile strength versus Mg content
for Example 1
alloys annealed at 250 F for 6 hours.
[0042] FIG. 4 is a graph illustrating tensile strength versus Mg content
for Example 1
alloys annealed at 400 F for 6 hours.
[0043] FIG. 5 is a graph illustrating tensile strength versus Mg content
for Example 1
alloys annealed at 450 F for 6 hours.
Page 15 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
[0044] FIG. 6 is a graph illustrating electrical conductivity versus Mg
content for the
Example 2 alloys.
[0045] FIG. 7 is a graph illustrating tensile strength versus Mg content
for Example 2
alloys annealed at 250 F for 6 hours for alloys without copper.
[0046] FIG. 8 is a graph illustrating tensile strength versus Mg content
for Example 2
alloys annealed at 450 F for 6 hours for alloys without copper.
[0047] FIG. 9 is a graph illustrating tensile strength versus Mg content
for Example 2
alloys annealed at 250 F for 6 hours for some alloys without copper and some
alloys with
copper.
[0048] FIG. 10 is a graph illustrating tensile strength versus Mg content
for Example 2
alloys annealed at 450 F for 6 hours for some alloys without copper and some
alloys with
copper.
[0049] FIG. 11 is a graph illustrating tensile strength versus Cu content
for Example 2
alloys annealed at 320 F for 6 hours.
[0050] FIG. 12 is a graph illustrating mass loss versus Mg content for
Example 2 alloys
annealed at 250 F for 6 hours for alloys without copper.
[0051] FIG. 13 is a graph illustrating electrical conductivity versus Mg
content for the
Example 3 alloys.
[0052] FIG. 14 is a graph illustrating yield strength versus Mg content for
Example 3
alloys annealed at 250 F for 6 hours.
[0053] FIGS. 15a is a graph illustrating electrical conductivity versus
yield strength for
various Example 3 alloys.
[0054] FIGS. 15b is a graph illustrating electrical conductivity versus
yield strength for
various Example 3 alloys.
[0055] FIGS. 15c is a graph illustrating electrical conductivity versus
yield strength for
various Example 3 alloys, with embodiments of performance trend lines
illustrated for various
alloys.
[0056] FIG. 16 is a graph illustrating mass loss versus Mg content for
Example 3 alloys
annealed at 250 F for 6 hours.
[0057] FIG. 17a is a graph illustrating thermal treatment temperature
versus yield strength
for various Example 2 and Example 3 alloys.
Page 16 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
[0058] FIG. 17b is a graph illustrating electrical conductivity versus
yield strength for
various Example 2 and Example 3 alloys.
[0059] FIG. 18a is a graph illustrating yield strength versus cold work
amount for various
Example 5 alloys.
[0060] FIG. 18b is a graph illustrating electrical conductivity versus cold
work amount for
various Example 5 alloys.
[0061] FIG. 19a is a graph illustrating thermal treatment temperature
versus yield strength
for various Example 5 alloys.
[0062] FIG. 19b is a graph illustrating thermal treatment temperature
versus yield strength
for various Example 5 alloys.
[0063] FIG. 20a is a graph illustrating electrical conductivity versus
yield strength for
various Example 6 alloys.
[0064] FIG. 20b is a graph illustrating electrical conductivity versus
yield strength for
various Example 6 alloys.
[0065] FIG. 20c is a graph illustrating mass loss versus yield strength for
various Example
6 alloys.
[0066] FIG. 20d is a graph illustrating electrical conductivity versus
yield strength for
various Example 6 alloys.
DETAILED DESCRIPTION
[0067] Example 1
[0068] Various 5xxx aluminum alloys are cast as book molds. The
experimental alloys
have the composition provided in Table 1, below.
Table 1 - Example 1 Alloy Compositions
(all values in weight percent)
Alloy Mg Mn Sc Zr
1 4.05 0.53 0.19 0.072
2 4.04 0.27 0.23 0.065
3 4.09 0.29 0.17 0.078
4 3.00 0.28 0.27 0.068
2.98 0.26 0.17 0.083
6 1.97 0.2 0.19 0.064
Page 17 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
7 4.04 0.16 0.066
8 2.96 0.19 0.064
9 1.96 0.21 0.064
1.88 0.21 0.08
11 5.06 0.18 0.06
12 5.02 0.13 0.074
13 4.09 0.15 0.072
14 4.02 0.078 0.078
=
Unless otherwise indicated, other than the above-listed ingredients, all of
the experimental
alloys 1-14 contained about 0.01 - 0.02 wt. % Ti, not greater than 0.01 wt. %
Cu, not greater
than 0.04 wt. % Si as an impurity, not greater than 0.10 wt. % Fe as an
impurity, not greater
than 0.02 wt. % Zn as an impurity, not greater than 0.05 wt. % each of any
other elements, and
with the other elements not exceeding 0.15 wt. % in total, the balance being
aluminum. Alloy
13 contained 0.94 wt. % Zn. Alloy 1 is similar to Alloy B of U.S. Patent No.
5,624,632, to
Baumann et al.
[0069] After casting, all of the samples are homogenized (preheated) using
the following
practice:
Linear ramp to 260 C (500 F) in 4 hrs
Soak at 260 C (500 F) +1- 2 C (5 F) for 5 hrs
Linear ramp to 290 C (550 F) in 2 hrs
Soak at 290 C (550 F) +7- 2 C (5 F) for 5 hrs
Linear ramp to 455 C (850 F) in 5 hrs
Soak at 455 C (850 F) +7- 2 C (5 F) for 4 hrs
Air cool
[0070] After homogenization, the book molds are processed to an H3y type
temper (e.g.,
an H38 temper). Specifically, the book molds are scalped to remove about 3 mm
(about
0.125") from both rolling faces; the sides of the book molds are also surface
machined. Prior
to hot rolling, all the book molds are given a heat-to-roll practice of from
about 425 to about
455 C (about 800 to 850 F) for from about 30 to about 60 minutes, after which
they are hot
rolled. The book molds are hot rolled using a six pass schedule to a final
gauge of about 7.1
Page 18 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
mm (about 0.28 inch). A final hot roll exit temperature of about 260 C (about
500 F) is
targeted. The pieces are air cooled, and then machined on the edges to
minimize edge
cracking. The material is then cold rolled about 80 to 85% to a nominal
thickness of about 1 to
1.1 mm.
[0071] Each of the experimental alloys is divided into various pieces. Some
of the pieces
are subjected to a thermal treatment in the form of an anneal. Other pieces
are not annealed.
Table 2 correlates the thermal treatments (or lack thereof) to the various
alloys pieces.
Table 2 - Anneal Treatments for Example 1 Alloys
Piece(s) Piece(s) Piece(s) Piece(s)
Piece(s) receiving receiving receiving receiving
Alloy receiving no anneal at anneal at anneal at anneal at
anneal 450 F for 6 400 F for 6 250 F for 6 475 F for 6
hours hours hours hours
1 1 a lb lc -- --
2 2a 2b 2c -- --
3 3a 3b 3c -- --
4 4a 4b -- 4c --
5a 5b Sc --
6 6a 6b 6d 6c --
7 7a 7b 7c -- --
8 8a 8b 8c --
9 9a 9b 9d 9c --
10a 10b --
11 1 1 a lib -- lie
12 12a 12b -- -- 12c
13 13a 13b 13c -- --
14 14a 14b 14c -- --
[0072] Each of the pieces is further split, and some of those splits are
treated (sensitized),
while others are not. The specific practice key is provided below, for
correlating the
mechanical properties of Table 3, below, to the sensitization category.
= A = No thermal treatment (F temper)
= B = 1 week at 100 C (212 F) ¨ Typical sensitization practice
= C = 1000 hrs at 85 C (185 F) ¨ Alternative 1 sensitization practice
= D = 100 hrs at 125 C (258 F) ¨ Alternative 2 sensitization practice
[0073] Material properties, including strength, ductility and corrosion
resistance are
measured for each piece, the results of which are provided in Table 3, below.
Tensile
Page 19 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
properties are measured in the longitudinal direction in accordance with ASTM
E8 and B557
using a sub-size specimen (about 100 mm). Duplicate tensile specimens are used
for each
condition. Corrosion properties are measured using the NAMLT (Nitric Acid Mass
Loss Test)
or "mass loss" test (ASTM G67-04) to assess intergranular corrosion
resistance. Duplicate
mass loss tests are run for each condition and the results are averaged. The
material is tested in
both the as-received (thermal treatment A) and thermally treated conditions
(B, C and D).
Thermal treatment can affect corrosion performance by accelerating the
precipitation of the f3
phase (Mg5A18), which can give an indication of potential long-term service
behavior.
Table 3 - Mechanical and Corrosion Properties of Example 1 Alloys
Piece
Sensitization Elect. Cond. TYS (L) UTS (L) EL % NAMLT
Category (% IACS) (1VIPa) (MPa)
(mg/cm2)
A 27.0 425.5 444.8 4.0
1.17
B 27.9 370.3 429.8 8.0
22.13
la C 28.2 373.0 433.5 8.0
31.51
D 28.1 356.8 420.5
8.5 25.12
A 27.7 326.8 396.0 9.0
1.18
B 28.2 323.8 396.8
11.0 7.32
lb C 28.2 328.5 404.8 10.0
18.26
D 28.2 327.5 398.5
9.5 17.11
A 27.8 337.5 399.5 9.0
6.04
B 28.2 338.5 407.0
8.5 16.21
lc C 28.1 344.3 412.3 8.5
19.44
D 28.4 339.3 409.3
9.0 21.88
A 29.0 415.8 439.8 3.5
1.26
B 30.1 357.8 416.0
9.0 20.82
2a C 30.3 365.8 424.8 7.5
29.14
D 30.4 346.3 412.3
8.5 23.80
A 29.7 319.3 387.0 10.0
1.27
B 30.3 317.3 387.8
10.0 7.10
2b C 30.0 321.0 390.0 9.0
17.12
D 30.3 315.0 388.0
10.5 15.23
A 30.1 322.5 388.0 9.5
4.46
B 30.4 322.3 389.5 9.5
10.49
2c C 30.1 333.8 403.5 9.5
18.78
D 30.5 329.3 398.8
10.0 21.31
i . .
A 28.2 419.3 436.3 3.0
1.04
B 29.1 362.0 413.5
6.0 18.01
3a C 29.2 354.8 411.5 8.5
27.84
D 29.3 350.0 409.0 6.0 22.64
Page 20 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Piece Sensitization Elect. Cond. TYS (L) UTS (L)
EL % NAMLT
Category (% IACS) (MPa) (MPa) (mg/cm2)
A 28.7 317.3 384.8 6.0 1.03
B 29.2 320.5 391.0 10.0 3.60
3b C 29.4 313.8 382.0 10.0 13.46
D 29.3 313.0 385.8 10.0 11.36
A 29.0 326.5 389.3 8.0 3.34
B 29.0 322.0 390.8 8.0 10.99
3c
C 29.4 324.8 391.0 8.5 17.62
D . 29.5 322.8 392.8 8.0
16.77
. ..
- ___________________________________________________________________
A 31.8 368.5 382.8 3.0 1.18 1
B 32.4 331.0 375.8 8.5 4.43
4a C 32.5 341.5 386.0 7.0 8.83
D 32.5 324.0 366.5 8.0 4.67
A 32.4 294.0 347.8 10.0 1.16
4b B 32.7 290.0 342.3 8.0 1.47
C 32.5 304.3 359.3 9.5 2.05
D 32.9 294.5 350.3 9.0 1.56
A 32.4 337.0 376.0 9.0 1.40
B 32.7 333.5 375.5 9.0 3.22
4c
C 32.5 345.0 388.3 8.0 5.68
D 32.6 333.8 , 377.0 8.0
5.25
lal
1
A 31.5 383.5 393.8 5 1.22
B 32.1 339.5 377.3 6 3.78
5a C 32.4 335.8 366.8 5.5 7.88
D 32.2 328 371.5 6 3.60
A 32.2 298.5 350.3 7 1.41
B 32.3 299.3 351 8 1.60
5b C 32.6 294.5 345 7 2.28
D 32.4 300.8 354.8 8 1.80
A 32.1 340.3 377.3 6 1.45
B 32.1 336.8 376 6 3.37
5c
C 32.2 337.5 378 7.5 5.86
D 32.4 329.8 372 6 5.16
'
,
A 36 329.5 337.5 5 1.11
6 B 37.1 301.25 330.75 7 1.09
a
C 36.7 306.5 335.8 6 1.25
D 36.9 296.5 326.75 8 1.14
A 36.8 268.25 309.5 8 1.04
6b B 37.4 268.5 312.75 9 1.05
C 37.1 268.3 309.5 7.5 1.09
D 37.1 267.25 308.25 8 1.04
6c A 36.3 303.5 328.25 5.5 1.14
Page 21 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Sensitization Elect. Cond. TYS (L) UTS (L) NAMLT
Piece El. 0/0
Category (')/0 IACS) (MPa) (1VIPa) (mg/cm2)
D 36.7 296.5 325.75 7
1.09
A 37.1 273.25 312.75 7 1.09
B 37.3 278.25 317.75 8.5
1.07
6d C 37 275.3 316 7.5 1.03
D 36.9 , 277 314:25 , 8
1.09
1
. -
A 33.2 380.25 398.75 4.5 1.18
B 34.9 322.75 374 7.5 20.38
7a C 35.1 334 393.5 8 26.29
D 35.1 312.75 375 8 20.78
A 34.2 272.25 353.25 11 1.14
B 34.2 275 351.5 11.5 9.25
7b C 34.2 282 355.5 10.5 15.31
D 34.6 270.75 343 10.5
12.56
A 34 279 344.5 10.5 1.37
B 34.5 295.5 364.75 10
6.46
7c C 34.4 293 366.8 11 12.10
D 34.6 291.75 365.5 10.5
10.55
'
A 37 352.25 367.5 3.5 1.07
B 38.4 306.25 349 7.5
6.49
8a C 38.4 307.5 353.8 7 11.36
D 38.6 293.5 343 7 5.37
A 38.5 261 323.75 10 1.04
B 38.7 262.75 324.75
10 1.59
8b C 38.3 267.5 327.8 8.5 3.28
D 38.3 264.75 326.25
10 2.02
A 37.9 310 348.75 7.5 1.62
B 38.2 305.25 349.25
8 6.20
8c C 38.2 306.5 353.8 7.5 9.18
D 38.2 300.25 345.75 9.5
6.58
A 42.4 315.25 323 5 1.00
B 43 280.25 313.5 7.5
1.07
9a C 43 286 316 7 1.38
D 43.3 275.75 308.25
7 0.98
A 43.2 247 291 8 0.98
B 43.6 248.5 292.5 8 0.96
9b C 43.5 250.5 298 7.5 0.99
D 43.5 248.5 295 9 0.95
A 43 283 312.25 7 1.01
9c
D 43.3 276.5 304.75 6 1.07
9d A 43.5 256.5 295.5 9 1.00
B 43.5 260.25 299.5 7
0.99
Page 22 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Sensitization Elect. Cond. TYS (L) UTS (L) NAMLT
Piece El. A
Category (% IACS) (MPa) (1VIPa) (mg/cm2)
C ' 43.2 260 300.5 8.5
1.03
D _ 43.4 257.5 297.25
7.5 0.99
A 42.1 322 329.5 4 1.04
a
B 42.3 293.3 321.3 6 1.06
A 42.3 292 319 6 1.03
B 42.3 289.5 318.9 6
1.07
10b C 42.7 290.5 319.3 7 1.12
D 42.9 282.3 313 6 1.09
r
1
,
A 30.2 429.25 456.5 5 1.48
B 31.7 344.25 421 8.5
31.86
11 a C 32.1 353.5 432.8 8 39.09
D 32.7 . 330.25 414.75 8 35.09
A 31.6 291.75 381.5 11 2.21
lib B 32 292 382.5 12 5.89
C 32.2 294 387.3 11 10.76
D 32.5 290.25 377.5
11 10.11
A 31.2 288.5 373 11.5 1.47
B 31.8 282.5 376.25
11.5 9.69
11c
C 31.8 296.5 389.5 11.5 14.86
D 32.1 289.75 386.25 11
15.70,
,
Qr "
A 30.2 430.75 463 4 1.72
B 32.7 390.25 458.5 7
42.13
12a C 33.2 399 459 6 49.58
D 34.1 365.75 442.75
7 44.51
A 32.7 290.25 369.5 8.5
3.30
12b B 33.6 288.5 383 10.5 4.07
C 33.6 288.8 ' 362 6 5.80
D 34.4 291 379 10.5
6.36
A 32.7 285 373.25 11 3.26
B 33.4 284.75 371.25 10.5
4.61
12c C 33.6 289 378.8 10.5
6.93
D 34.1 282.75 372 10 6.83
. 1 ,
______________________________________________________________________ .....
A 33 395.75 414.5 5 1.14
13 B 34.2 331.25 386.75 7 21.21
a
C 34.3 333.3 394 8 26.75
D 34.3 318 380.5 8.5
22.19
A 34.3 279.25 350.5 10.5
1.10
13b B 34.5 265.25 340.25 9.5
9.91
C 34.3 283.8 357.8 11 14.84
D 34.9 279.25 350.5 10.5
12.61
Page 23 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Piece
Sensitization Elect. Cond. TYS (L) UTS (L) EL 0 NAMLT
/0
Category (% IACS) (MPa) (MPa)
(mg/cm2)
A 34.6 280.25 348.5 11.5 1.67
13c 34.7 292 357 8.5 6.35
34.7 294.5 363 8.5 11.23
35 291 355.25 7.5 9.50
A 33 383.5 399.25 4 1.22
34.5 310.25 363.75 6 14.77
14a 34.6 321.5 380 7 24.68
35.1 300.25 361.5 7.5 21.16
A 34 253.75 327.25 11 1.13
34.4 243 317.5 12 7.59
14b 34.4 262 335.8 11.5 12.73
34.6 247.25 320.5 10.5 10.28
A 34.4 262.25 327.75 11 1.69
34.7 275.25 345.5 10 4.59
14c 34.5 276.3 349.3 10 8.26
34.7 274 344.5 10 7.90
[0074] As shown in Table 3 and FIG. 1, irrespective of anneal or
sensitization category,
electrical conductivity generally changes linearly as a function of magnesium
content. Alloys
having more than 4 wt. % Mg realize poor electrical conductivity (e.g., <
35.0% IACS). The
alloys having less than about 3% Mg generally realize good electrical
conductivity, especially
when Mn is absent, as shown in FIG. 2. However, alloys containing low Mg and
no Mn have
low strength as illustrated in FIGS. 3-5. However, alloys having Sc and Zr
tend to have
increased strength. For example, alloys 8-10 have low Mg and no Mn, but with
Sc and Zr
realize strengths near or above 300 MPa when annealed at 250 F for 6 hours.
Example 2 - Affect of Sc and Zr
[0075] Based on the Example 1 data, additional book mold testing is
conducted on low
Mg, no Mn 5xxx aluminum alloys. Nineteen additional experimental book molds
are produced
using generally the same practice described in Example 1. Two additional
alloys (B-1 and B-
2) having a composition similar to Alloy B of U.S. Patent No. 5,624,623 to
Baumann et al. are
also produced in book mold form. The experimental materials and the Baumann
materials are
cold rolled about 80 to 85% to a nominal thickness of about 1 to 1.1 mm.
Aluminum
Association alloys 5454, 5086, 5052 are produced in book mold form, and
processed to a final
Page 24 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
gauge of about 1 to 1.1 mm with 80 to 85% cold work using conventional 5xxx
production
practices.
[0076] The Example 2 alloy compositions are provided in Table 4, below. The
thermal
treatment chart is provided as Table 5, below. The mechanical and corrosion
data are provided
in Table 6, below. Only some of the alloys are tested for corrosion
resistance.
Table 4 - Example 2 Alloy Compositions
(all values in weight percent)
Alloy Mg Mn Sc Zr Cu
15 0.93 -- -- --
16 1.00 -- 0.066 0.092 --
17 0.95 -- 0.14 0.13 --
18 3.57 -- -- --
19 3.49 -- 0.065 0.091 --
20 3.64 -- 0.14 0.14 --
21 3.98 -- 0.063 0.092 --
22 0.48 -- 0.14 0.16 --
23 1.97 --
24 1.87 -- -- 0.078 --
25 1.99 -- 0.066 -- --
26 1.96 -- 0.064 0.074 --
27 1.92 -- -- 0.14 --
28 1.91 -- 0.14 -- --
29 1.96 -- 0.13 0.14 --
30 1.89 -- -- 0.15
31 3.58 -- 0.062 0.075 0.16
32 3.44 -- 0.064 0.068 0.24
33 3.53 -- 0.066 0.075 0.50
AA5454 2.80 0.63 -- -- 0.07
AA5086 3.95 0.44 -- -- 0.07
AA5052 2.31 -- -- 0.06
B-1 4.04 0.53 0.17 0.079
B-2 3.89 0.53 0.12 0.063
Unless otherwise indicated below, other than the above-listed ingredients, all
of the
experimental alloys 15-33 and alloys AA5454, AA5086, AA5052, B-1 and B-2
contained
about 0.01 - 0.02 wt. % Ti, not greater than 0.01 wt. % Cu, not greater than
0.06 wt. % Si as an
impurity, not greater than 0.10 wt. % Fe as an impurity, not greater than 0.02
wt. % Zn as an
impurity, not greater than 0.05 wt. % each of other elements, and with the
other elements not
exceeding 0.15 wt. % in total, the balance being aluminum. The prior art
Aluminum
Page 25 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Association alloys 5454, 5086, and 5052 contain not more than 0.13 wt. % Si
and not more
than 0.25 wt. % Fe. Alloy 5454 also contains 0.089 wt. % Cr and 0.11 wt. % Zn.
Alloy 5086
contains 0.083 wt. % Cr. Alloy 5052 contains 0.2 wt. % Cr.
Table 5 - Anneal Treatments for Example 2 Alloys
Piece(s) Piece(s) Piece(s)
Piece(s)
Piece(s) receiving receiving receiving
receiving
Alloy receiving no anneal at anneal at anneal at
anneal at
anneal 450 F for 6 400 F for 6 250 F for 6
320 F for 6
hours hours hours hours
15 15a 15b -- 15c --
16 16a 16b -- 16c --
17 17a 17b -- 17c --
18 18a 18b 18c -- --
19 19a 19b 19c 19d 19e
20 20a 20b 20c -- --
21 21a 21b 21c -- --
22 22a 22b -- 22c --
23 23a 23b -- 23c --
24 24a 24b -- 24c --
25 25a 25b -- 25c --
26 26a 26b -- 26c --
27 27a 27b -- 27c --
28 28a 28b -- 28c --
29 29a 29b -- 29c --
30 30a 30b -- 30c --
31 31a 31b 31c 31d 31e
32 32a 32b 32c 32d 32e
33 33a 33b 33c 33d 33e
AA5454 5454a 5454b -- 5454c --
AA5086 5086a 5086b 5086c -- --
AA5052 5052a 5052b -- 5052c --
B-1 B-1-a B-1-b B-1-c -- --
B-2 B-2-a B-2-b B-2-c -- --
Table 6 - Mechanical and Corrosion Properties of Example 2 Alloys
Sensitization Elect.TYS (L) UTS (L) NAMLT
Piece Cond. El. %
Category (MPa) (MPa)
(mg/cm)
15a A 52.6 221.5 226.0 4.0 _
15b A 53.2 145.5 174.8 11.0
15c A 53.2 2045. 219.3 7.0
¨
16a A 51.7 247.5 252.0 4.0
16b A 51.8 197.5 224.5 10.0
Page 26 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Sensitization Elect.TYS (L) UTS (L) NAMLT
Piece Cond. El. %
Category (mg/cm)
(% IACS) aVis Pa) __ (IVIPa)
16c A 51.3 233.5 247.8 7.0 1
.., ,
I 1
___________________________________________________________ ,---
17a A 50.4 269.3 274.5 6.0
17b A 50.8 229.8 255.8 7.0
17c A 51.2 255.8 271.8 7.0
1 . M III = 1
18a A 37.6 351.8 363.8 5.0 1
18b A 38.5 174.5 264.3 20.0
18c A 38.6 205.8 274.8 15.0
19a A 36.4 372.0 384.3 4.0 ,
19b A 36.8 250.0 313.0 11.5
-'-';
19e A 37.5 258.3 316.7 11.0
-,,
19c A 36.5 258.0 316.3 11.0 1.11
19c B 37.2 264.0 324.8 11.0 6.06
19c D 36.7 262.0 321.3 11.0 8.65
19d A 36.2 321.3 362.0 7.5 5.05 __
19d B 37.1 314.5 360.3 8.0 17.47
19d D 37.2 301.8 353.0 9.5 18.98
19e A 36.1 297.5 343.3 9.0 5.73
19e B 37.3 295.3 346.3 7.5 12.13
19e D 36.9291.5 343.5 8.5 15.27
ME 1111 IMO
20a A 35.3 393.3 409.5 4.0
20b A 36.2286.0 348.3 12.0
20c A 36.3 297.5 351.5 10.0
--r-
,
1
L 1
21a A 34.2 391.5 400.8 4.0
4
21b A 35.0 255.8 326.0 13.0
--;i
21c A 35.3 267.8 332.5 ______ 11.0
1111 ' 0
,,,
22a A 54.7 245.5 252.0 5.0
22b A 55.1 213.0 237.5 9.0
22c A 54.3 241.3 255.3 9.0
1
- , - r
23a A- 45.4- 277.0-- 283.5 4.5 h
23b A 46.0 158.0 208.5 14.0
23c A 46.1 239.5 262.0 7.0
23c A 44.5 239.5 262.0 7.0 0.98
23c B 45.6 235.8 263.3 7.0 1.05
23c D 46.1 228.8 258.5 __ 8.5 1.04
- Fo.
24a A 43.8 279.5 284.8 5.0
24b A 44.5 164.8 214.5 16.0
Page 27 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Sensitization Elect.TYS (L) UTS (L) NAMLT
Piece Cond. El. %
Category (MPa) (MPa)(mg/cm)
%
( IACS)
24c A 44.8 242.8 263.8 7.0
-
_ 1
25a A 44.6 281.3 287.8 5.0 -
25b A 45.1 166.8 219.3 15.0
25c A 45.2 242.5 265.0 7.0
26a A 43.5 300.8 305.8 5.0 /
26b A 44.6 214.0 253.3 10.0 ,
26c A 44.3 263.3 284.0 7.0
26c A 43.7 263.3 284.0 7.0 1.02
26c B 44.0 268.0 293.3 7.0 1.02
26cD ________________________ 44.5 277.3 ___ 281.8 7.0 1.04
_ ____________ , ri
,
L.
27a A 42.7 280.5 285.5 4.0
1
27b A 43.3 171.3 219.3 17.0
27c A 43.3 246.0 267.3 7.0
28a A 44.6 290.0 298.3 5.0 ,
28b A 45.0 182.8 232.5 13.0
28c A 45.1 251.3 276.5 7.0
29a A 43.8 322.5 328.3 6.0
29b A 44.3 260.8 293.8 9.0
29c A 44.2 289.3 312.8 7.0 a A
29c A 43.4 289.3 312.8 7.0 1.01
29c B 43.9 295.0 320.0 7.0 1.00
29c D 44.1 289.5 316.3 7.5 1.02
- -- 7
_______________________________ 1 . _____________ .., ___________
30a A 44.5 - 295.8 298.8 4.0
30b A 45.6 181.3 227.0 10.0 1
30c A 45.0 269.8 292.3 7.0 .
30c A 43.6 269.8 292.3 7.0 0.89
30c B 44.7 278.3 307.0 7.0 0.91
30c D 44.5 _______________ 281.8 315.5 8.5 __ 0.93
1 - - , -,
-Am
31b A 37.0 1
259.5 326.5 12.0 ;
274.8 330.3 10.0
31c A 37.0
31c A 36.3 274.8 330.3 10.0 1.17
31c B 37.3 282.3 338.5 11.0 6.13
31c D 36.5 281.0 338.8 10.5 9.52
31d A 35.7 352.3 391.3 7.0 3.14
31d B 36.3 350.3 396.8 8.5 14.67
31d D 36.3 344.0 392.5 8.5 18.38
Page 28 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Piece Cond. El. 0/0
Category (MPa) (MPa) (mg/cm)
31e A 35.6 340.0 384.0 8.5 5.20
31e B 36.4 340.8 387.3 8.5 12.27
31e D 36.4 338.8 385.0 9.0 15.74
32a A 35.9 402.0 414.8 4.0
32b A 37.2 263.0 327.3 11.5
32c A 37.3 284.3 338.8 10.5 i
32c A 36.3 284.3 338.8 10.5 1.18
32c B 37.4 291.0 345.8 10.0 8.37
32c D 36.9 288.0 346.5 10.5 10.42
32d A 35.5 362.5 399.5 8.0 3.44
32d B 36.2 363.5 407.0 8.5 13.73
32d D 36.3 359.3 405.3 8.5 18.76
32e A 35.9 349.8 395.5 7.0 5.12
32e B 36.5 348.8 394.0 9.0 12.68
32e D 36.5 348.0 394.5 9.0 16.02
I
...,, i. _____________________________________________
33a A 35.6' 419.5 430.8 4.5
33b A 37.0 278.0 336.8 12.0
33c A 37.2 298.5 349.5 10.0 _
33c A 36.4 298.5 349.5 10.0 1.62
33c B 37.3 301.0 353.8 9.0 8.06
33c D 36.8 302.0 357.3 9.5 8.81
33d A 36.3 376.0 414.8 7.0 3.30
33d B 36.9 379.3 423.0 8.5 12.27
33d D 36.3 370.8 417.3 9.0 16.40
33e A 36.3 356.8 400.0 9.0 4.31
33e B 37.2 355.0 401.3 8.0 12.03
33e D 36.6 351.0 396.8 9.0 13.87
______ - _____________________________________________________________ - 1
5052a A 35.5 320.5 324.5 4.0 I
5052b A 36.0 220.0 259.0 10.0
5052c A ___________ 36.0 283.0 307.5 7.0
-II _
5086a A 28.9 426.8 438.0 5.0
5086b A 30.1 271.8 337.5 13.0
5086c _______ A __________ 30.0 302.5 __ 358.8 10.0
I ____________________________________________________
5454a A 32.1 373.5 379.5- 4.0
5454b A 33.1 237.3 271.8 13.0
5454c _______ A 32.7 328.5 361.0 7.0 ________ i
,
I ______________________________________________________________________ I
B-1-a A 28.5 439.3 454.8 5.0 1.26
B-1-a B 29.8 374.5 429.8 8.0 27.86
Page 29 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Sensitization Elect.TYS (L) UTS (L) NAMLT
Piece Cond. El. %
Category (MPa) (MPa) (mg/cm)
B-1-a C 29.4 370.3 429.5 8.5 34.36
B-1-a D 30.5 355.5 416.5 8.0 29.68
B-1-b A 29.4 324.3 388.3 10.0 1.22
B-1-b B 29.8 324.8 391.5 10.5 14.85
B-1-b C 29.5 327.3 391.8 8.5 31.91
B-1-b D 30.2 324.5 389.3 10.5 23.74
B-1-c A 29.5 338.3 394.8 8.0 3.35
B-1-c B 29.8 334.8 405.0 9.5 16.58
B-1-c C 29.9 339.5 404.0 9.0 25.79
B-1-c D 30.5 334.0 402.5 9.0 25.11 .
- -
B-2-a A 28.8 436.0 450.3 5.0 1.20-
B-2-a B 30.0 369.8 421.3 7.0 27.39
B-2-a C 30.1 369.5 427.3 8.0 37.12
B-2-a D 30.5 354.0 409.0 5.0 31.90
B-2-b A 29.9 320.5 384.8 10.5 1.15
B-2-b B 30.1 321.8 385.8 10.0 14.20
B-2-b C 30.1 322.0 385.3 9.0 30.83
B-2-b D 30.5 319.0 384.8 10.5 23.43
B-2-c A 29.8 334.8 392.5 9.0 3.04
B-2-c B 30.1 331.5 397.3 10.0 15.23
B-2-c C 30.1 333.5 395.8 9.0 27.44
B-2-c D 30.6 331.8 392.8 7.5 25.62
[0077] As shown in FIG. 6, alloys having more than about 3.5 wt. % Mg do
not have good
electrical conductivity. Indeed, of the prior art alloys, only alloy 5052 has
a conductivity
above 35% IACS even though it has low Mg (about 2.3 wt. %).
[0078] FIGS. 7 and 8 illustrate the synergistic effect of combining Sc and
Zr. Alloys that
contain no Sc or Zr, or alloys that contain only one of Sc or Zr generally
realize much lower
strengths than alloys containing even moderate amounts of Sc + Zr. Alloys
containing higher
amounts of Sc + Zr generally realize much higher strengths than alloys without
Sc and/or Zr.
Indeed, as illustrated by Example alloys 23 and 29, about a 40 MPa strength
difference is
realized at the 250 F anneal (FIG. 7), and about a 100 MPa strength difference
is realized at the
450 F anneal (FIG. 8) for alloys that contain Sc+Zr as opposed to alloys that
contain no Sc or
Zr.
[0079] FIGS. 9-11 illustrate the benefit of using Cu additions to improve
strength. As
illustrated in FIGS. 9 and 10, alloys with Cu additions realize improved
strength, with or
Page 30 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
without Sc+Zr. As shown in FIG. 9, alloy 30, which contains no Sc or Zr, but
contains 0.15
wt. % Cu, realizes about the same strength as alloys containing lower levels
of Sc+Zr for the
250 F anneal. Alloys that contain all of Cu, Sc, and Zr realize significant
strength
improvements, as shown by the alloys having about 3.5 wt. % Mg. Similar
results are realized
with the 450 F anneal (FIG. 10). As shown in FIG. 11, the influence of Cu
appears to be non-
linear. Cu additions of 0.15 wt. % and 0.24 wt. % are shown to significantly
benefit strength
over alloys containing no Cu. The increase to 0.50 wt. % Cu did not
dramatically increase
strength beyond that achieved by the 0.24 wt. % Cu alloy.
[0080] FIG. 12 illustrates the benefit of using lower amounts of Mg so as
to achieve an
acceptable level of intragranular corrosion resistance. Alloys having about
3.5 wt. % Mg
realize poor intergranular corrosion resistance. Alloys having 2 wt. % Mg
realize good
intragranular corrosion resistance, all realizing a mass loss of not greater
than 5 mg/cm2. As
shown in FIG. 12, Cu additions tend to decrease the nitric acid mass loss
values. Alloys 31-33,
which all contain some Cu, have lower intragranular corrosion than their
counterpart alloys
without Cu. Thus, Cu additions of up to 0.50 wt. % should not detrimentally
affect, and may
even benefit, the intragranular corrosion resistance of the alloys.
[0081] With respect to pitting and exfoliation resistance, several 2 wt. %
Mg alloys, with
and without Cu, are subjected to corrosion resistance testing in accordance
with a modified
version of ASTM B117. The alloys are tested in the annealed condition and
after sensitization
treatments B or C are applied. The samples are alternatively immersed (Al) in
a 3.5% NaC1
solution (without stress), with 8 hours spray and 16 hours soak. The Al test
is run for exposure
intervals of 6, 10, 20 and 40 days. All alloys performed well, with no
evidence of any
corrosion attack.
Example 3 - Affect of Copper
[0082] Based on the Example 2 data, additional book mold testing is
conducted on low
Mg, no Mn 5xxx aluminum alloys, with Sc+Zr, and sometimes with Cu. Fifteen
additional
experimental book molds are produced using generally the same practice
described in Example
1. The compositions of the additional book molds are provided in Table 7,
below. Pieces of
the Example 3 alloys received no thermal treatment (piece "a") or were
annealed at 250 F for 6
hours (piece "b"). The mechanical and corrosion data are provided in Table 8,
below.
Table 7- Example 3 Alloy Compositions
(all values in weight percent)
Page 31 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Alloy Mg Mn Sc Zr Cu
34 1.92 -- 0.13 0.16
35 1.90 -- 0.084 0.12 0.21
36 1.91 -- 0.084 0.17 0.21
37 1.96 -- 0.13 0.12 0.21
38 1.95 -- 0.14 0.17 0.21
39 1.94 -- 0.086 0.11 0.36
40 1.93 -- 0.13 0.16 0.36
41 2.93 -- 0.079 0.12 0.21
42 2.94 -- 0.14 0.16 0.20
43 0.49 -- 0.14 0.16 0.20
44 0.97 -- 0.14 0.16 0.20
45 1.46 -- 0.14 0.16 0.20
46 2.45 -- 0.13 0.16 0.21
47 2.71 -- 0.13 0.16 0.21
48 3.23 -- 0.13 0.16 0.20
Unless otherwise indicated below, other than the above-listed ingredients, all
of the
experimental alloys 34-48 contained about 0.01 wt. % Ti, not greater than 0.05
wt. % Si as an
impurity, not greater than 0.17 wt. % Fe as an impurity, not greater than 0.01
wt. % Zn as an
impurity, not greater than 0.05 wt. % each of other elements, and with the
other elements not
exceeding 0.15 wt. % in total, the balance being aluminum.
Table 8 - Mechanical and Corrosion Properties of Example 3 Alloys
Piece
ASensitization Elect. Cond. TYS (L) UTS (L) N MLT
E
Category ('% IACS) (MPa) (MPa)
PA(mg/cm2)
34a A 43.1 316.5 326.8 5.0
34b A 43.1 286.5 311.3 7.0 0.98
34b B 42.4 287.5 315.3 7.0 1.01
34b D 42.3 281.3 311.0 8.0 1.02
35a A 41.9 337.0 343.3 4.0 - --
35b A 42.0 314.3 340.8 6.0 1.04
35b B 41.5 313.8 346.5 8.0 1.03
35b D 41.9 317.0 354.0 8.0 1.03
1111 li M
_
36a A 41.7 343.8 349.3 4.0
36b A 41.7 324.0 349.8 6.0 1.04
36b B 41.6 326.8 357.5 7.0 1.01
36b D 41.8 326.3 358.5 8.0 1.02
37a A 42.2 344.0 348.5 4.0 --
Page 32 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Piece
Sensitization Elect. Cond. TYS (L) UTS (L) E,, NAMLT
Category (% IACS) (MPa) (MPa) 17 (mg/cm2)
37b A 42.5 317.8 346.5 6.0 1.07
37b B 41.4 314.3 354.3 8.0 1.04
37b _________ D 42.0 323.3 364.8 9.0 1.02
IMIIIIII
38a A 41.8 342.8 353.0 4.0 --
38b A 41.7 323.0 352.5 8.0 1.06
38b B 41.2 326.3 358.0 8.0'
1.03
38b D 41.8 . 324.8 360.3 8.0
1.04
IIII
39a A 41.5 361.3 369.3 4.0 --
39b A 41.4 340.3 370.0 7.5 1.10
39b B 41.2 340.0 373.5 8.0 1.11
39b D 41.6 343.5 _____ 378.0 8.0
1.10
-
40a A 40.9 ' 370.8 375.5 4.0 --
40b A 40.9 349.8 379.0 7.0 1.16
40b B 40.9 352.3 386.0 8.0 1.16
40b D 41.4 354.0 390.3 10.0
1.14
! ii-
.
......_
_
41a A = 36.8 383.5 392.8 4.0 --
41b A 37.2 349.0 381.3 7.0 1.28
41b B 37.1 344.3 385.5 8.0 3.73
41b D 37.7. 346.8 385.5 9.5
5.46
-0-81--
., ..._s. , . _......._ 1
42a A 37.4 384.0 398.5 4.0 --
42b A 37.6 355.8 392.8 8.0 1.36
42b B 36.9 354.0 395.0 10.0
3.39
42b D 37.7 351.0 395.8 10.0
4.61
_
__________________________________________ 1
43a A 52-3 269.8 275.5 4.0 --
43b A 52.4 269.8 287.0 6.0 0.84
43b B 51.9 273.5 297.8 8.0 0.80
43b _________ D 52.7 ___________ 275.8 303.0 10.0
0.82
_ -
_________________________________________ ' K _
44a A 48.4 301.0 305.3 4.0 --
44b A 48.4 294.3 313.0 6.0 0.88
44b B 48.3 297.0 323.8 8.0 0.84
44b _________ D _______ 49.0 300.3 329.3 8.0
0.84
_
7
1
, ,
45a A 44.9 324.0 327.5 4.0 --
45b A 44.9 310.3 333.0 8.0 1.02
45b B 44.6 317.5 350.0 8.0 0.92
45b __________ D 45.5 308.3 _____ 343.8 8.0
0.92
_ .
46a A 38.9 366.8
379.0 I 5:6 --
Page 33 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
o
Piece
Sensitization Elect. Cond. TYS (L) UTS (L) El
NAMLT
k
Category (% IACS) (MPa) (MPa) I
" (mg/cm2)
46b A 39.1 341.0 369.8 7.5 1.07
46b B 38.7 336.0 376.3 8.0 1.27
46b D 39.4 337.5 377.5 8.0 1.27
47a A 38.2 377.8 390.0 5.0
47b A 38.4 341.5 379.3 8.0 1.15
47b B 38.3 344.5 385.3 7.0 1.93
47b D 38.6 343.8 387.5 8.0 2.29
48a A 35.0 401.5 414.3 4.5
48b A 35.6 362.0 403.8 8.0 1.86
48b B 35.6 363.8 406.8 8.0 8.63
48b D 36.3 356.8 406.5 8.0 11.81
[0083] As shown in FIG. 13, electrical conductivity increases with
decreasing Mg content,
as shown in the previous examples. As shown in FIG. 14, the use of Sc and Zr
in combination
with the Cu additions of 0.20 to 0.36 wt. % can significantly increase
strength. Indeed, the
alloys containing only about 2 wt. % Mg realize a yield strength of at least
about 310 MPa.
[0084] FIGS. 15a-15c illustrate the electrical conductivity versus yield
strength
performance of various Example 3 alloys. As shown in FIG. 15a, the Type B and
D sensitized
alloys having about 0.2 wt. % Cu realize a generally linear EC-TYS
relationship. The Type B
alloys have a trend line of EC = -0.1854(TYS) + 101.87 with an R2 value of
0.9276. The Type
D alloys have a trend line of EC = -0.2055(TYS) + 109.01 with an R2 value of
0.9672. FIG.
15b shows that the same general linear trend exists for the non-sensitized
alloys.
[0085] FIG. 15c illustrates one manner of characterizing the new 5xxx
aluminum alloy
products. The new 5xxx aluminum alloy products are bounded by a minimum yield
strength
(L) of 270 MPa and a minimum electrical conductivity of 35% IACS, as shown by
the solid
lines. These properties are measured after the aluminum alloy is annealed at
250 F for 6 hours.
In this graph, a trend line of having an equation of EC = -0.195(7'YS) +
Intercept is shown,
where the intercept shifts based on the amount of Sc, Zr and/or Cu in the
alloy. A minimum
performance line is shown, having an equation of EC = -0.195(TYS) + 96. This
minimum
performance line correlates to the performance of the low Sc+Zr and no Cu
alloys. As the
amount of Sc+Zr and/or copper present in the new 5xxx aluminum alloys
increases, the
performance line shifts to the right by changing the intercept, but keeping
the same slope (-
0.195). For all Sc+Zr alloys with 0.2 wt. % Cu, the intercept is about 102-108
(an intercept of
Page 34 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
105.4 is illustrated). For the 0.36 wt. % Cu alloys having lower levels of
Sc+Zr, the intercept
is about 107-109. For the 0.36 wt. % Cu alloys having higher levels of Sc+Zr,
the intercept is
about 109-111.
[0086] The performance trend correlates to the alloy performance of the
Example 2 alloys
that were also annealed at 250 F for 6 hours. For instance, Alloys 19 and 26,
which are no
copper, low Sc+Zr alloys (0.156 and 0.138 wt. % Sc+Zr, respectively),
generally meet the
requirements set forth above for the Type B and D alloys. Of these alloys, one
of the 0.138 wt.
% Sc +Zr alloys barely misses the criteria of FIG. 15c, having a yield
strength of 268 MPa.
This indicates that the minimum Sc+Zr level may be at least 0.14 wt. %, such
as when lower
amounts of Mg are utilized in the alloy.
[0087] Alloy 29, which contains no copper and higher levels of Sc+Zr alloy
(0.27 wt. %
Sc+Zr), falls within the bounds of the performance requirements of FIG. 15c,
having an
intercept of in the range of from about 100.5 to about 101.5, depending on
sensitization type (B
or D).
[0088] Alloy 30, with no Sc+Zr, but 0.15 wt. % Cu, falls within the
performance bounds of
FIG. 15c, but will likely have low retained strength due to the absence of
Sc+Zr, as shown by
Alloy 23 of Example 4, below.
[0089] Alloy 31, with lower levels of Sc+Zr (0.137), and 0.16 wt. % Cu,
falls within the
performance bounds of FIG. 15c, having an intercept in the range of from about
103 to about
104.5, depending on sensitization type (B or D).
[0090] Alloy 32, with lower levels of Sc+Zr (0.132), and 0.24 wt. % Cu,
falls within the
performance bounds of FIG. 15c, having an intercept in the range of from about
106 to about
107.5, depending on sensitization type (B or D).
[0091] Alloy 33, with lower levels of Sc+Zr (0.137), and 0.50 wt. % Cu,
falls within the
performance bounds of FIG. 15c, having an intercept in the range of from about
108.5 to about
111, depending on sensitization type (B or D).
[0092] Table 9, below, correlates the Cu and Sc+Zr levels to the intercept
of the
performance line in accordance with the data (sorted by increasing Cu level,
which appears to
have the most prominent affect on the shift of the intercept).
Table 9 - Performance line intercepts for various new 5xxx aluminum alloys
Cu Line
Alloys Sc+Zr (wt. %)
(wt. %) Intercept
Page 35 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Cu Line
Alloys Sc+Zr (wt. A))
(wt. %) Intercept
19, 26, 34 0 0.138 to 0.29 96-101.5
31 0.16 0.137 103 - 104.5
35-37, 41 0.2 0.20 - 0.25 102-105
38, 42-48 0.2 0.29 - 0.31 104-108
33 0.24 0.132 106-107.5
39 0.36 0.196 107-109
40 0.36 0.29 109-111
34 0.50 0.141 108.5 - 111
Based on these trends, it is expected that the new 5xxx aluminum alloys having
high amounts
of Cu and Sc+Zr could have a performance line intercept of 113, or higher.
[0093] The new
5xxx aluminum alloys generally have good corrosion resistance when Mg
levels are kept below 3.25 wt. %, such as below 3.0 wt. %. As shown in FIG.
16, intragranular
corrosion is high when the alloys contain more than 3.25 wt. % Mg. Indeed,
once the alloys
exceed about 3 wt. % Mg, the intragranular corrosion increases dramatically.
[0094] Salt
spray tests similar to those described in Example 2 are conducted on a
selection
of the Example 3 alloys containing from about 2 wt. % to about 3 wt. % Mg, all
of which also
contain copper. The test samples are visually observed after 6, 10, 20, 40,
and 80 days (20
days is the specification requirement). After 20 days of exposure, the samples
do not show any
evidence of attack for any of the thermal treatment conditions, although the
higher copper
alloys appear slightly darker in color. Even after 40 and 80 days exposure
there is little or no
attack.
Example 4 - Retained Strength
[0095] Several
Example 2 and Example 3 alloys are exposed to varying elevated
temperatures for 100 hours, after which their electrical conductivity and
mechanical properties
are tested. The results of these tests are provided in Table 10, below. All
tested alloys were
those alloys that had been previously annealed at 250 F for 6 hours.
Table 10 - Strength Retention Properties
Elect. Percent Drop
Treatment Time Treatment Temp Cond. TYS (L) in TYS
El%
Alloy (hrs) ( F) (% (MPa) (relative to
IACS) no TT)
23 0 None 44.5 239.5 7.0
23 100 260 46.1 228.8 4% 8.5
23 100 300 45.8 205.0 14% 8.0
23 100 350 45.7 179.5 25% 11.0
Page 36 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Elect. Percent Drop
Treatment Time Treatment Temp Cond. TYS (L) in TYS
El%
Alloy (hrs) ( F) ( /0 (MPa) (relative to
IACS) no TT)
23 100 400 45.7 153.8 36% 13.0
23 100 450 45.5 100.3 58% 20.0
23 100 500 45.9 74.5 69% 25.0
, ____________________________________________________ ... __
29 0 None 43.4 289.3 _ 7.0
29 100 260 44.1 289.5 0% 7.5
29 100 300 43.3 271.8 6% 6.0
29 100 350 43.4 264.3 9% 6.0
29 100 400 43.3 255.8 12% 7.5
29 100 450 43.4 250.8 13% 8.0
29 100 500 43.4 245.5 15% 8.0
35 0 None 42.0 314.3 -- 6.0
35 100 260 41.9 317.0 -1% 8.0
35 100 300 42.4 302.5 4% 8.0
35 100 350 42.9 268.5 15% 8.0
35 100 400 43.2 252.8 20% 9.0
35 100 450 43.7 242.0 23% 9.0
35 100 _______ 500 43.5 233.0 26% 8.5
- T --
=
38 0 None 41.7 323.0 -- 8.0
38 100 260 41.8 324.8 -1% 8.0
38 100 300 42.1 312.5 3% 8.0
38 100 350 42.9 282.5 13% 7.5
38 100 400 43.2 268.0 17% 8.0
38 100 450 43.2 261.8 19% 9.0
38 100 500 42.6 254.0 21% 8.0
1 __
i _________________ . _____________________________________________________
.
40 0 None 40.9 349.8 -- 7.0
40 100 260 41.4 354.0 -1% 10.0
40 100 300 42.5 329.0 6% 8.0
40 100 350 43.5 295.8 15% 8.0
40 100 400 43.7 274.8 21% 10.5
40 100 450 44.0 264.8 24% 9.0
40 100 500 44.1 255.5 27% 8.5
,
42 0 None 37.6 355.8 -- 8.0
42 100 260 37.7 351.0 1% 10.0
Page 37 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Elect. Percent Drop
Treatment Time Treatment Temp Cond. TYS (L) inP
k a)in TYS
El%
Alloy (hrs) CF) (0/0 fit ir \
(relativeT to
T)
IACS) no
42 100 300 37.6 335.3 6% 8.0
42 100 350 37.9 303.5 15% 8.0
42 100 400 38.1 290.3 18% 10.0
42 100 450 38.3 280.3 21% 11.0
42 100 500 38.4 273.3 23% 10.5
,
43 0 None 52.4 269.8 -- 4.0
43 100 260 52.7 275.8 -2% 10.0
43 100 300 53.1 264.5 2% 8.0
43 100 350 54.3 237.0 12% 8.0
43 100 400 54.7 220.0 18% 8.0
43 100 450 54.9 215.3 20% 8.5
43 100 500 54.8 213.5 21% 9.0
44 0 None 48.4 294.3 -- 6.0
44 100 260 49.0 300.3 -2% 8.0
44 100 300 49.1 286.0 3% 8.5
44 100 350 50.0 254.8 13% 8.0
44 100 400 50.4 239.0 19% 8.0
44 100 450 50.4 233.5 21% 8.0
44 100 500 50.6 227.3 23% __ 8.0 ,
_
5454 0 None 32.7 328.5 -- 7.0
5454 100 300 32.9 301.0 8% 8.0
5454 100 350 33.0 276.0 16% 8.5
5454 100 400 33.1 250.0 24% 12.0
5454 100 450 33.4 123.3 62% 21.0
5454 100 500 33.2 125.5 62% 20.0
__.
5052 0 None 36.0 283.0 -- 7.0
5052 100 300 35.3 269.0 5% 8.0
5052 100 350 35.3 239.5 15% 9.0
5052 100 400 35.5 226.0 20% 10.5
5052 100 450 35.7 131.8 53% 17.5
5052 100 500 35.7 100.8 64% 22.5
Page 38 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
[0096] As
illustrated in FIGS. 17a-17b, the new 5xxx aluminum alloys containing both Sc
and Zr realize improved strength retention capabilities. The new 5xxx aluminum
alloys realize
a drop in yield strength of only about 15-27% when processed at 500 F for 100
hours relative
to their counterpart alloys having no thermal treatment. As a comparison,
alloy 23, which
contained no Sc or Zr, realizes a yield strength decrease of 69%, and alloys
5052 and 5454
realize yield strength decreases of 64% and 62%, respectively. Electrical
conductivity
generally remains unchanged irrespective of thermal treatment. This indicates
that the new
5xxx aluminum alloys are well-suited for high temperature applications in
which strength
retention is important, such as automotive electrical conductor applications.
Example 5- Cold Work Amount
[0097]
Hot rolled, but non-cold rolled portions of alloys 38, 43, and 48, from above,
are
cold rolled 30%, 50%, 65% and 83%. The alloys received no thermal treatment
(piece "a") or
were annealed at 250 F for 6 hours (piece "b"). The mechanical data are
provided in Table 11,
below.
Table 11 - Mechanical Properties of Example 5 Alloys
Alloy Elect.
Cold Work Sensitization TYS (L) UTS (L)
Piece Cond.
Eryo
(0/0) Category
(% IACS) (MPa) (MPa)
38 38a 83 A 40.8 337.0 346.0 5.5
38 38b 83 A 41.5 319.5 349.3
9.0
38 38b 83 B 41.8 318.5 354.8
9.0
38 38b 83 D 42.0 317.5 356.5
10.5
38 38a 65 A 41.0 326.5 336.3
6.0
38 38b 65 A 41.5 301.5 332.3
8.0
38 38b 65 B 42.1 301.0 338.5 9.5
38 38b 65 D 42.1 302.8 345.5
10.0
38 38a 50 A 41.1 326.0 334.8
6.0
38 38b 50 A 41.6 298.3 331.0
8.0
38 38b 50 B 42.2 297.8 338.0
9.0
38 38b 50 D 42.1 300.3 343.8
10.0
38 38a 30 A 41.2 312.8 325.5 6.5
38 38b 30 A 41.5 285.0 317.8
8.0
38 38b 30 B 42.0 289.3 330.3
10.0
38 38b 30 D 42.2 291.3 ____ 331.3
10.0
: 3
,
43 43a 83 A 51.9 259.5 263.0
5.5
43 43b 83 A 52.1 253.8 271.5
6.0
43 43b 83 B 52.9 254.0 282.5
7.0
43 43b 83 D 52.9 259.8 289.5
8.0
43 43a 65 A 52.0 260.8 263.8
6.0
Page 39 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Alloy Elect
Cold Work Sensitization TYS (L) UTS (L)
Pi . ece Cond.
El
%
(%) Category
(% IACS) (MPa) (MPa)
43 43b 65 A 52.1 251.5 269.0
8.0
43 43b 65 B 52.9 255.3 280.3
8.0
43 43b 65 D 52.8 259.5 288.0
10.0
43 43a 50 A 51.7 254.5 258.0
6.0
43 43b 50 A 52.0 243.8 263.0
9.0
43 43b 50 B 52.8 247.8 274.8
9.0
43 43b 50 D 52.8 253.5 283.7
9.0
43 43a 30 A 51.8 241.8 245.5
6.0
43 43b 30 A 52.2 237.0 256.5
8.0
43 43b 30 B 52.8 236.8 263.8
10.0
43 43b 30 D 52.9 240.8 270.3
10.0
mom - 1
48 48a 83 A 34.7 391.8 406.0
6.0
48 48b 83 A 35.3 354.8 393.3
9.5
48 48b 83 B 36.0 352.0 400.5
9.5
48 48b 83 D 36.1 352.0 398.0
10.0
48 48a 65 A 34.8 384.0 399.3
5.5
48 48b 65 A 35.6 341.3 384.5
10.0
48 48b 65 B 36.0 335.5 390.5
10.0
48 48b 65 D 36.1 343.5 396.8
10.0
48 48a 50 A 34.7 366.0 383.5
6.5
48 48b 50 A 35.3 327.3 373.5
10.0
48 48b 50 B 36.0 326.5 380.3
10.0
48 48b 50 D 35.9 325.5 375.8
10.0
48 48a 30 A 35.0 352.3 369.5
6.0
48 48b 30 A 35.3 312.0 368.5
9.0
48 48b 30 B 35.9 318.8 373.0
10.0
48 48b 30 D 36.0 316.3 371.8
11.5
As shown in FIGS. 18a-18b, depending on Mg level, the alloys containing about
2 wt. % and
about 3.25 wt. % Mg achieve an electrical conductivity of at least about 35%
and a
longitudinal tensile yield strength of at least about 270 MPa, even with low
amounts of cold
work. This suggests that some alloys may be useful in high strength electrical
applications
even with low amounts of cold work (e.g.,? 10% CW). The 0.5 wt. % Mg alloy
(Alloy 43)
did not quite achieve a tensile yield strength of 270 MPa, but could
potentially reach 270 MPa
as shown in Example 3, above. This suggests that at least 0.75 wt. % or 1.0
wt. % Mg and/or
from 0.35 to 0.45 wt. % Cu may be required in some instance to achieve a
tensile yield
strength of at least 270 MPa. In these embodiments, at least 50% cold work may
be required.
Page 40 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
[0098] The alloys are also tested for strength retention by prolonged
exposure to elevated
temperature as shown in Table 12 below. As shown in FIGS. 19a-19b, the alloys
all realize
good strength retention, irrespective of cold work amount.
Table 12 - Strength Retention Properties
Percent
Cold Treatment Treatment
TYS (L) Drop in TYS
Alloy Work Time Temp El /o
(%) (hrs) (T)
(MPa) (relative to
no TT)
38 83 0 None 319.5 -- 9.0
38 83 100 260 317.5 0.6% 10.5
38 83 100 300 306.5 4.1% 9.0
38 83 100 350 275.5 13.8% 9.0
38 83 100 400 262.3 17.9% 9.0
38 83 100 450 254.0 20.5% 9.0
38 83 100 500 245.0 23.3% 9.0
38 65 0 None 301.5 -- 8.0
38 65 100 260 302.8 -0.4% 10.0
38 65 100 300 298.5 1.0% 9.0
38 65 100 350 271.8 9.9% 9.0
38 65 100 400 260.3 13.7% 9.0
38 65 100 450 252.0 16.4% 9.0
38 65 100 500 242.0 19.7% 9.0
38 50 0 None 298.3 -- 8.0
38 50 100 260 300.3 -0.7% 10.0
38 50 100 300 289.8 2.8% 9.0
38 50 100 350 265.3 11.1% 9.5
38 50 100 400 249.3 16.4% 10.0
38 50 100 450 245.5 17.7% 10.0
38 50 100 500 241.5 19.0% 10.0
38 30 0 None 285.0 -- 8.0
38 30 100 260 291.3 -2.2% 10.0
38 30 100 300 281.0 1.4% = 10.0
38 30 100 350 259.8 8.8% 10.0
38 30 100 400 244.3 14.3% 10.0
38 30 100 450 233.0 18.2% 10.0
38 30 100 500 227.5 20.2% 10.0
u-
1
_ _
43 83 0 None 253.8 -- 6.0
43 83 100 260 259.8 -2.4% 8.0
43 83 100 300 252.0 0.7% 10.0
43 83 100 350 225.3 11.2% 9.0
Page 41 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Percent
Cold Treatment Treatment
Alloy Work Time Temp TYS (L)
Drop in TYS El%
(%) (hrs) ( F) (MPa) (relative to
no TT)
43 83 100 400 201.3 20.7% 9.0
43 83 100 450 203.8 19.7% 9.0
43 83 100 500 199.8 21.3% 9.0
43 65 0 None 251.5 -- 8.0
43 65 100 260 259.5 -3.2% 10.0
43 65 100 300 246.5 2.0% 9.5
43 65 100 350 223.5 11.1% 10.0
43 65 100 400 195.0 22.5% 9.0
43 65 100 450 197.0 21.7% 9.5
43 65 100 500 200.8 20.2% 10.0
43 50 0 None 243.8 -- 9.0
43 50 100 260 253.5 -4.0% 9.0
43 50 100 300 242.0 0.7% 10.0
43 50 100 350 216.0 11.4% 10.0
43 50 100 400 204.3 16.2% 9.5
43 50 100 450 198.3 18.7% 10.0
43 50 100 500 199.3 18.3% 10.0
43 30 0 None 237.0 -- 8.0
43 30 100 260 240.8 -1.6% 10.0
43 30 100 300 240.0 -1.3% 10.0
43 30 100 350 213.3 10.0% 10.0
43 30 100 400 196.8 17.0% 10.0
43 30 100 450 191.5 19.2% 9.0
43 30 100 500 194.0 18.1% 9.0
_
I
48 83 0 None 354.8 -- 9.5
48 83 100 260 352.0 0.8% 10.0
48 83 100 300 338.5 4.6% 9.0
48 83 100 350 306.5 13.6% 9.0
48 83 100 400 290.8 18.0% 9.5
48 83 100 450 283.8 20.0% 10.0
48 83 100 500 275.8 22.3% 11.0
48 65 0 None 341.3 -- 10.0
48 65 100 260 343.5 -0.6% 10.0
48 65 100 300 325.3 4.7% 10.0
48 65 100 350 299.0 12.4% 11.0
48 65 100 400 284.5 16.6% 11.5
48 65 100 450 272.8 20.1% 11.5
Page 42 of 55
CA 02815834 2013-04-24
WO 2012/058542
PCT/US2011/058293
Percent
Cold Treatment Treatment
TYS (L) Drop in TYS
Alloy Work Time TempEl%
(MPa) (relative to
(0/0)
'hr ( F)
no TT)
48 65 100 500 264.8 22.4% 11.0
48 50 0 None 327.3 -- 10.0
48 50 100 260 325.5 0.5% 10.0
48 50 100 300 321.5 1.8% 10.0
48 50 100 350 293.8 10.2% 10.0
48 50 100 400 280.0 14.5% 11.0
48 50 100 450 263.8 19.4% 13.0
48 50 100 500 258.5 21.0% 13.0
48 30 0 None 312.0 -- 9.0
48 30 100 260 316.3 -1.4% 11.5
48 30 100 300 311.3 0.2% 11.5
48 30 100 350 286.5 8.2% 11.0
48 30 100 400 265.3 15.0% 1.0
48 30 100 450 252.8 19.0% 12.5
48 30 100 500 250.0 19.9% 13.5
i. ... 1 ....i
,
x
Example 6 - Additional Testing of Alloy Compositions
[0099] Additional book mold testing is conducted on low Mg, no Mn 5xxx
aluminum
alloys, with Sc+Zr, and sometimes with Cu. Fourteen additional experimental
book molds are
produced using generally the same practice described in Example 1. The
compositions of the
additional book molds are provided in Table 13, below. Pieces of the Example 6
alloys
received no thermal treatment (piece "a") or were annealed at 250 F for 6
hours (piece "b").
The mechanical and corrosion data are provided in Table 14, below.
Table 13 - Example 6 Alloy Compositions
(all values in weight percent)
Alloy Mg Mn Sc Zr Cu Other
49 1.96 -- 0.15 0.14 0.21 --
50 1.95 -- 0.15 0.11 0.21 0.088
Si; 0.10 Fe
51 1.95 -- 0.16 0.10 0.20 0.088
Si; 0.15 Fe
52 1.95 -- 0.16 0.11 0.20 0.13
Si; 0.14 Fe
53 2.00 -- 0.16 0.12 0.21 0.17
Si; 0.20 Fe
54 1.97 -- 0.17 0.12 0.21 0.21
Si; 0.24 Fe
55 3.46 -- 0.067 0.052 0.053
56 3.40 -- 0.07 0.055 0.094 --
Page 43 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Alloy Mg Mn Sc Zr Cu Other
57 3.44 -- 0.068 0.045 0.15 --
58 3.41 -- 0.075 0.059 0.34 --
59 1.95 0.15 0.12 0.21 0.03 Cr
60 1.95 -- 0.14 0.12 0.21 0.06 Cr
61 2.00 -- 0.16 0.11 0.21 0.14 Cr
62 1.96 -- 0.15 0.10 0.2 0.21 Cr
[00100] Unless otherwise indicated, other than the above-listed ingredients,
all of the
experimental alloys 49-63 contained about 0.01 wt. % Ti, not greater than 0.05
wt. % Si as an
impurity, not greater than 0.10 wt. % Fe as an impurity, not greater than 0.01
wt. % Zn as an
impurity, the balance being aluminum and other elements, the combined amount
of other
elements not exceeding 0.05 wt. % each, and not more than 0.15 wt. % in total.
Table 14 - Mechanical Properties of Example 6 Alloys
Sensitization Elect. Cond. TYS (L) UTS (L)
NAMLT
Piece Er3/0
Category (% IACS) (MPa) (MPa)
(mg/cm)
49a A 40.6 340.3 344.5 4.0
49b A 43.5 320.5 348.0 5.5 0.83
49b B 42.4 325.5 360.3 6.0 0.83
49b D 42.7 325.8 362.8
7.0 0.83
.
_
1 -
50a A 41.3 331.5 335.8 4.0 . __
50b A 43.4 312.8 338.3 6.0 0.89
50b B 42.4 316.5 349.5 6.0 0.89
50b _______ D 42.3 316.8 353.0 6.0
0.92
. ___________________________________________ - _____
51a A 40.5 332.0 339.5 4.0
51b A 42.5 312.0 340.0 6.0 1.03
51b B 42.5 315.3 350.8 7.0 1.03
51b D 42.8 315.0 353.3 7.0
0.99
_
____ _ ____________________________________________
52a A 41.2 333.0 338.0 4.0
52b A 43.4 313.0 339.8 7.0 1.02
52b B 42.8 314.8 349.3 7.0 1.04
52b D 43.2 314.5 350.8 7.0 1.07
53a A 41.5 327.0 332.8 3.5
53b A 43.6 312.8 338.5 6.5 1.07
53b B 42.8 312.5 343.8 7.0 1.06
53b D ____________________ 43.0 314.0 347.3 7.0
1.05
54a A 42.2 324.5 330.0 4.0 --
Page 44 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
Sensitization Elect. Cond. TYS (L) UTS (L)
NAMLT
Piece El%
Category (% IACS) (MPa) (MPa)
(mg/cm2)
54b A 44.2 307.0 334.0 7.0
1.14
54b B 43.4 311.3 343.3 7.0
1.14
54b D 43.4 307.0 346.8 7.0
1.13
____ , _____________________________________________________________________
55a A 3411 357.0 369.5 4.0 --
55b A 35.7 308.3 350.0 7.0
2.77
55b B 35.4 309.3 356.8 8.0
12.41
55b D 35.9 305.0 353.8 8.0
15.31
=
,
. õ _____________________________________________________________________
56a A 34.2 367.0 379.0 4.0 --
56b A 36.2 323.0 364.3 8.0
2.28
56b B 35.8 319.8 365.0 7.5
10.49
56b D 35.9 320.3 367.5 7.0
14.26
M I M Wi
,
57a A 34.6 364.3 378.8 4.0
57b A 36.6 328.0 369.0 8.0
2.12
57b B 36.4 325.8 373.3 9.0
9.03
57b D 36.7 320.5 370.8 9.0 __
12.93
,
.
1
.. ... .......:.
.
. .
58a A 33.8 386.3 400.8 4.0 --
58b A 35.5 350.0 398.3 7.0
2.46
58b B 36.2 352.0 398.0 8.0
9.04
58b D 35.8 348.8 397.5 8.0
13.57
,
,
-1.- ...L._
59a A 39.4 330.8 -338.5 3.5
--
59b A 41.2 319.8 346.0 7.0
0.95
59b B 40.9 316.3 353.8 7.0
0.92
59b _______ D 41.0 ______ 320.8 359.5 8.5
0.93
60a A 38.1 345.5 350.0 3.0 --
60b A 39.7 317.3 344.0 8.0
0.92
60b B 39.3 321.8 357.3 8.0
0.93
60b D 39.5 321.0 358.3 8.0
0.96
r . -
li.../...
61a A 36.1 339.5 348.8 5.0 --
61b A 37.7 319.8 351.3 6.0
0.94
61b B 37.1 324.8 359.8 7.0
0.97
61b D 37.1 324.5 362.0 8.0
1.00
..
,
- ________________________________________
62a A 34.1 342M 351.0 5.0 --
62b A 35.5 328.5 355.5 6.0
1.00
62b B 35.1 330.3 365.8 8.5
1.01
62b D 35.1 332.0 367.5 8.0
1.00
Page 45 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
[00101] As shown in FIG. 20a, alloys having lower levels of silicon and iron
generally
achieve a better combination of strength and electrical conductivity. Alloy 54
with 0.21 wt. %
Si and 0.24 wt. % Fe achieved about 20 MPa lower strength than Alloy 49 with
0.04 wt. % Si
and 0.092 wt. % Fe. These results indicate that iron and silicon levels should
be maintained
below 0.25 wt. %, such as any of the amounts of Fe and Si described in the
Summary, above.
[00102] As shown in FIG. 20b, alloys with about 3.5 wt. % Mg achieve a lower
electrical
conductivity, around 35% IACS. These high Mg alloys realize increasing
strength with
increasing copper, but electrical conductivity is relatively unaffected. As
shown in FIG. 20c,
these alloys realize poorer corrosion resistance, generally having a mass loss
around 15
mg/cm2. These results indicate that Mg should be maintained below 3.5 wt. %,
such as not
greater than 3.25 wt. %, as shown above. For increased strength, copper may be
included in an
amount of at least 0.05 wt. %, or more, as described above. For corrosion
resistance, copper
should be restricted to 0.50 wt. %, or less, such as any of the amounts
described in the
Summary, above.. Silver (Ag) is expected to have the same strength impact as
copper, but with
a lesser impact on corrosion resistance, and thus can be added as a substitute
for copper, or in
combination with copper in the above identified amounts, as well as in the
amounts identified
in the Summary, above.
[00103] As shown in FIG. 20d, chromium should be avoided as it has a
detrimental impact
on electrical conductivity. Alloy 62 with 0.21 wt. % Cr and about 0.01 wt. %
Ti had a lower
electrical conductivity than the alloys with less chromium. Vanadium is known
to have a
similar impact on electrical conductivity. These results indicate that the
alloys should contain
not greater than 0.30 wt. % total of Cr, V and Ti (i.e., the total combined
amounts of Cr, V, and
Ti does not exceed 0.30 wt. %), such as any of the amounts of Cr, V, and Ti
described in the
Summary, above. Ti may be beneficial for grain refining, and thus the new 5xxx
aluminum
alloys may include at least 0.005 wt. % Ti, in some instances. Nickel (Ni) and
cobalt (Co) are
known to have a lesser impact on electrical conductivity than chromium, and
thus may be
included in the new 5xxx aluminum alloy in an amount of up to 0.50 wt. % total
Ni plus Co
(i.e., the total combined amounts of Ni and Co does not exceed 0.50 wt. %),
such as any of the
amounts of Ni plus Co described in the Summary, above.
[00104] While various embodiments of the new technology described herein have
been
described in detail, it is apparent that modifications and adaptations of
those embodiments will
occur to those skilled in the art. However, it is to be expressly understood
that such
Page 46 of 55
CA 02815834 2013-04-24
WO 2012/058542 PCT/US2011/058293
modifications and adaptations are within the spirit and scope of the presently
disclosed
technology.
Page 47 of 55
