Note: Descriptions are shown in the official language in which they were submitted.
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ALUMINUM ALLOY SUITABLE FOR THE HIGH SPEED PRODUCTION OF
ALUMINUM BOTTLE AND THE PROCESS OF MANUFACTURING THEREOF
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No.
62/094,358, filed December 19, 2014, which is incorporated by reference herein
in its
entirety.
FIELD OF THE INVENTION
The invention is related to a new aluminum alloy. In one aspect, the invention
further
relates to a method of producing highly shaped aluminum products, such as
bottles or cans,
using the aluminum alloy.
BACKGROUND
Many modern methods of aluminum can or bottle manufacture require highly
shapeable aluminum alloys. For shaped bottles, the manufacturing process
typically involves
first producing a cylinder using a drawing and wall ironing (DWI) process. The
resulting
cylinder is then formed into a bottle shape using, for example, a sequence of
full-body
necking steps, blow molding, or other mechanical shaping, or a combination of
these
processes. The demands on any alloy used in such a process or combination of
processes are
complex.
There is a need for alloys that can sustain high levels of deformation during
mechanical shaping or blow molding for the bottle shaping process and that
function well in
the DWI process used to make the starting cylindrical preform.
Further requirements of the alloy are that it must be possible to produce a
bottle which
meets the targets for mechanical performance (e.g., column strength, rigidity,
and a minimum
bottom dome reversal pressure in the final shaped product) with lower weight
than the current
generation of aluminum bottles. The only way to achieve lower weight without
significant
modification of the design is to reduce the wall thickness of the bottle. This
makes meeting
the mechanical performance requirement even more challenging.
A final requirement is the ability to form the bottles at a high speed. To
achieve a
high throughput (e.g., 1000 bottles per minute) in commercial production, the
shaping of the
bottle must be completed in a very short time. Thus, methods are needed for
making
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preforms from the alloy at high speeds and levels of runability, such as that
demonstrated by
the current can body alloy AA3104. AA3104 contains a high volume fraction of
coarse
intermetallic particles formed during casting and modified during
homogenization and
rolling. These particles play a major role in die cleaning during the DWI
process, helping to
remove any aluminum or aluminum oxide build-up on the dies, which improves
both the
metal surface appearance and also the runability of the sheet.
In meeting all the requirements as stated above, different embodiments of the
alloys
and methods of the current invention have the following specific chemical
composition and
properties (all elements are expressed in weight percent (wt. %)).
SUMMARY
Provided herein are novel alloys that display high strain rate formability at
elevated
temperatures. The alloys can be used for producing highly shaped aluminum
products,
including bottles and cans.
In one embodiment, the aluminum alloy described herein comprises about 0.15-
0.50
% Si, 0.35-0.65 % Fe, 0.05-0.30% Cu, 0.60-1.10 % Mn, 0.80-1.30% Mg, 0.000-
0.0080 %
Cr, 0.000-0.500% Zn, 0.000-0.080% Ti, up to 0.15 % of impurities, with the
remainder as
Al (all in weight percentage (wt. %)). Also provided herein are products
(e.g., bottles and
cans) comprising an aluminum alloy as described herein.
Further provided herein are methods of producing the aluminum alloys
described. In
one embodiment, the methods include direct chill (DC) casting of an aluminum
alloy as
described herein to form a metal product, homogenizing the metal product, hot
rolling the
metal product to produce a metal sheet, cold rolling the metal sheet (e.g.,
with a 60 % to 90 %
thickness rejection), optionally recrystallization annealing the rolled sheet,
cold rolling the
annealed sheet, and stabilization annealing the rolled sheet. Products (e.g.,
bottles or cans)
obtained according to the methods are also provided herein.
Other objects and advantages of the invention will be apparent from the
following
detailed description of embodiments of the invention.
BRIEF DESCRIPTION OF THE FIGURES
Figure 1 is a scanning transmission electron microscopy (STEM) micrograph of
an
aluminum alloy according to an embodiment of the invention showing a
substructure with
average geometrically necessary boundary (GNB) spacing larger than 300 nm.
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Figure 2 is a STEM micrograph of an aluminum alloy according to an embodiment
of
the invention showing a GNB-containing substructure with average GNB spacing
larger than
2.5 [tm.
Figure 3 is a STEM micrograph of an aluminum alloy according to an embodiment
of
the invention showing a GNB-containing substructure with average GNB spacing
larger than
8 [tm.
Figure 4 is a STEM micrograph of an aluminum alloy according to an embodiment
of
the invention showing a GNB-free substructure.
DETAILED DESCRIPTION OF THE INVENTION
Definitions and Descriptions
The terms "invention," "the invention," "this invention" and "the present
invention"
used herein are intended to refer broadly to all of the subject matter of this
patent application
and the claims below. Statements containing these terms should be understood
not to limit
the subject matter described herein or to limit the meaning or scope of the
patent claims
below.
As used herein, the meaning of "a," "an," or "the" includes singular and
plural
references unless the context clearly dictates otherwise.
Reference is made in this application to alloy temper or condition. For an
understanding of the alloy temper descriptions most commonly used, see
"American National
Standards (ANSI) H35 on Alloy and Temper Designation Systems."
The following aluminum alloys are described in terms of their elemental
composition
in weight percentage (wt. %) based on the total weight of the alloy. In
certain embodiments
of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for
the sum of
the impurities.
Aluminum Alloy Systems
In one aspect, the invention is related to a new aluminum alloy system for
aluminum
bottle applications. The alloy compositions exhibit good high strain rate
formability at
elevated temperatures. The high strain rate formability is achieved due to the
elemental
compositions of the alloys.
In one aspect, the invention provides highly formable alloys for use in
manufacturing
highly shaped cans and bottles. In one aspect, the invention provides
chemistry and
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manufacturing processes that are optimized for the high-speed production of
aluminum
bottles.
In one embodiment, the aluminum alloy comprises:
0.15-0.50 wt. % Si,
0.35-0.65 wt. % Fe,
0.05-0.30 wt. % Cu,
0.60-1.10 wt. % Mn,
0.80-1.30 wt. % Mg,
0.000-0.080 wt. % Cr,
0.000-0.500 wt. % Zn,
0.000-0.080 wt. % Ti, and
up to about 0.15 wt. % impurities, with the remainder as Al.
In another embodiment, the aluminum alloy comprises:
0.20-0.40 wt. % Si,
0.40-0.60 wt. % Fe,
0.08-0.20 wt. % Cu,
0.70-1.00 wt. % Mn,
0.85-1.22 wt. % Mg,
0.000-0.070 wt. % Cr,
0.000-0.400 wt. % Zn,
0.000-0.070 wt. % Ti,
up to about 0.15 wt. % impurities, with the remainder as Al.
In yet another embodiment, the aluminum alloy comprises:
0.22-0.38 wt. % Si,
0.42-0.58 wt. % Fe,
0.10-0.18 wt. % Cu,
0.75-0.98 wt. % Mn,
0.90-1.15 wt. % Mg,
0.000-0.060 wt. % Cr,
0.000-0.300 wt. % Zn,
0.000-0.060 wt. % Ti,
up to about 0.15 wt. % impurities, with the remainder as Al.
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In still another embodiment, the aluminum alloy comprises:
0.27-0.33 wt. % Si,
0.46-0.54 wt. % Fe,
0.11-0.15 wt. % Cu,
0.80-0.94 wt. % Mn,
0.93-1.07 wt. % Mg,
0.000-0.050 wt. % Cr,
0.000-0.250 wt. % Zn,
0.000-0.050 wt. % Ti,
up to about 0.15 wt. % impurities, with the remainder as Al.
In still another embodiment, the aluminum alloy comprises:
0.25-0.35 wt. % Si,
0.44-0.56 wt. % Fe,
0.09-0.16 wt. % Cu,
0.78-0.94 wt. % Mn,
0.90-1.10 wt. % Mg,
0.000-0.050 wt. % Cr,
0.000-0.250 wt. % Zn,
0.000-0.050 wt. % Ti,
up to about 0.15 wt. % impurities, with the remainder as Al.
In still another embodiment, the aluminum alloy comprises:
0.12-0.28 wt. % Si,
0.32-0.52 wt. % Fe,
0.09-0.16 wt. % Cu,
0.78-0.96 wt. % Mn,
0.90-1.10 wt. % Mg,
0.000-0.050 wt. % Cr,
0.000-0.250 wt. % Zn,
0.000-0.050 wt. % Ti,
up to about 0.15 wt. % impurities, with the remainder as Al.
In another embodiment, the aluminum alloy comprises:
0.27-0.33 wt. % Si,
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0.46-0.54 wt. % Fe,
0.11-0.15 wt. % Cu,
0.80-0.94 wt. % Mn,
0.93-1.07 wt. % Mg,
0.000-0.050 wt. % Cr,
0.000-0.250 wt. % Zn,
0.000-0.050 wt. % Ti,
up to about 0.15 wt. % impurities, with the remainder as Al. In one aspect,
the aluminum
alloy comprises about 0.296 wt. % Si, about 0.492 wt. % Fe, about 0.129 wt. %
Cu, about
0.872 wt. % Mn, about 0.985 wt. % Mg, about 0.026 wt. % Cr, about 0.125 wt. %
Zn, about
0.010 wt. Ti, up to about 0.15 wt. % impurities, with the remainder as Al.
In certain aspects, the disclosed alloy includes silicon (Si) in an amount
from about
0.12% to 0.50% (e.g., from 0.20% to 0.40%, from 0.22% to 0.38 %, from 0.25 %
to 0.35
%, from 0.27 % to 0.33 %, or from 0.12 % to 0.28 %) based on the total weight
of the alloy.
For example, the alloys can include 0.12%, 0.13 %, 0.14%, 0.15 %, 0.16%,
0.17%, 0.18 %,
0.19%, 0.20%, 0.21 %, 0.22%, 0.23 %, 0.24%, 0.25 %, 0.26%, 0.27%, 0.28%,
0.29%,
0.30%, 0.31 %, 0.32%, 0.33 %, 0.34%, 0.35 %, 0.36%, 0.37%, 0.38 %, 0.39%,
0.40%,
0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, or
0.50 % Si. All
expressed in wt. %.
In certain aspects, the alloy also includes iron (Fe) in an amount from about
0.35 % to
about 0.65 % (e.g., 0.40 % to 0.60 %, from 0.42 % to 0.58 %, from 0.44 % to
0.56 %, from
0.46 % to 0.54 %, or from 0.32 % to 0.52 %) based on the total weight of the
alloy. For
example, the alloys can include 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40
%, 0.41 %,
0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51
%, 0.52 %,
0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 % 0.61 %, 0.62 %,
0.63 %,
0.64 %, or 0.65 % Fe. All expressed in wt. %.
In certain aspects, the disclosed alloy includes copper (Cu) in an amount from
about
0.05 % to about 0.30% (e.g., from 0.08% to 0.20%, from 0.10% to 0.18%, from
0.09% to
0.16 %, from 0.10% to 0.16%, from 0.109 % to 0.16 %, or from 0.11 % to 0.15 %)
based on
the total weight of the alloy. For example, the alloys can include 0.05 %,
0.06 %, 0.07 %,
0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%,
0.19%, 0.20%, 0.21 %, 0.22%, 0.23 %, 0.24%, 0.25 %, 0.26%, 0.27%, 0.28 %,
0.29%, or
0.30 % Cu. All expressed in wt. %.
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In certain embodiments, the disclosed alloy includes manganese (Mn) in an
amount
from about 0.60% to about 1.10% (e.g., about 0.70% to 1.00%, from 0.75 % to
0.98%,
from 0.78 % to 0.94 %, from 0.78 % to 0.96 %, or from 0.80 % to 0.94 %, )
based on the total
weight of the alloy. For example, the alloy can include 0.60 %, 0.61 %, 0.62
%, 0.63 %, 0.64
%, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %,
0.74 %, 0.75
%, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %,
0.85 %, 0.86
%, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %,
0.96 %, 0.97
%, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %,
1.07 %, 1.08
%, 1.09%, or 1.10% Mn. All expressed in wt. %.
In some embodiments, the disclosed alloy includes magnesium (Mg) in an amount
from about 0.80% to about 1.30% (e.g., from 0.85 % to 1.22%, from 0.90% to
1.15 %,
from 0.90 % to 1.10 %, or from 0.93 % to 1.07 %) based on the total weight of
the alloy. For
example, the alloy can include 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %,
0.86 %, 0.87
%, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %,
0.97 %, 0.98
%, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %,
1.08 %, 1.09
%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20
%, 1.21 %, 1.22%, 1.23 %, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29% or 1.30 Mg.
All
expressed in wt. %.
In certain aspects, the alloy includes chromium (Cr) in an amount up to about
0.80 %
(e.g., from 0 % to 0.05 %, 0 % to 0.06 %, from 0 % to 0.07 %, from 0 % to 0.08
%, from 0.03
to 0.06 %, from 0.005 % to 0.05 %, or from 0.001 % to 0.06 %) based on the
total weight of
the alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004
%, 0.005 %,
0.006%, 0.007%, 0.008 %, 0.009%, 0.010%, 0.011 %, 0.012%, 0.013 %, 0.014%,
0.015
%, 0.016 %, 0.017 %, 0.018 %, 0.019 %, 0.020 %, 0.021 %, 0.022 %, 0.023 %,
0.024 %,
0.025 %, 0.026 %, 0.027 %, 0.028 %, 0.029 %, 0.030 %, 0.031 %, 0.032 %, 0.033
%, 0.034
%, 0.035 %, 0.036 %, 0.037 %, 0.038 %, 0.039 %, 0.040 %, 0.05 %, 0.051 %,
0.052 %, 0.053
%, 0.054 %, 0.055 %, 0.056 %, 0.057 %, 0.058 %, 0.059 %, 0.060 %, 0.065 %,
0.070 %,
0.075 %, or 0.08 % Cr. In certain aspects, Cr is not present in the alloy
(i.e., 0 %). All
expressed in wt. %.
In certain aspects, the alloy described herein includes zinc (Zn) in an amount
up to
about 0.5 % (e.g., from 0 % to 0.25 %, from 0 % to 0.2 %, from 0 % to 0.30 %,
from 0 % to
0.40 %, from 0.01 % to 0.35 %, or from 0.01 % to 0.25 %) based on the total
weight of the
alloy. For example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %,
0.005 %,
0.006 %, 0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %,
0.06 %, 0.07
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%, 0.08 %, 0.09 o, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 o,
0.17 %, 0.18
%, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %,
0.28 %, 0.29
%, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %,
0.39 %, 0.40
%, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, or
0.5000 Zn.
In certain cases, Zn is not present in the alloy (i.e., 0 %). All expressed in
wt. %.
In certain aspects, the alloy includes titanium (Ti) in an amount up to about
0.08 A
(e.g., from 0 A to 0.05 %, 0 A to 0.06 %, from 0 A to 0.07 %, from 0.03 to
0.06 %, from
0.005 A to 0.05 %, or from 0.001 A to 0.06 %) based on the total weight of
the alloy. For
example, the alloy can include 0.001 %, 0.002 %, 0.003 %, 0.004 %, 0.005 %,
0.006 %,
0.007 %, 0.008 %, 0.009 %, 0.01 %, 0.011 %, 0.012 %, 0.013 %, 0.014 %, 0.015
%, 0.016 %,
0.017 %, 0.018 %, 0.019 %, 0.02 %, 0.021 %, 0.022 %, 0.023 %, 0.024 %, 0.025
%, 0.026 %,
0.027 %, 0.028 %, 0.029 %, 0.03 %, 0.031 %, 0.032 %, 0.033 %, 0.034 %, 0.035
%, 0.036 %,
0.037 %, 0.038 %, 0.039 %, 0.04 %, 0.05 %, 0.051 %, 0.052 %, 0.053 %, 0.054 %,
0.055 %,
0.056 %, 0.057 %, 0.058 %, 0.059 %, 0.06 %, 0.065 %, 0.07 %, 0.075 %, or 0.08
A Ti. In
certain aspects, Ti is not present in the alloy (i.e., 0 %). All expressed in
wt. %.
Optionally, the alloy compositions can further include other minor elements,
sometimes referred to as impurities, in amounts of about 0.15 % or below, 0.14
% or below,
0.130o or below, 0.120o or below, 0.11 % or below, 0.100o or below, 0.090o or
below, 0.08
% or below, 0.07 % or below, 0.06 % or below, 0.05 % or below, 0.04 % or
below, 0.03 % or
below, 0.02 % or below, or 0.01 % or below. These impurities may include, but
are not
limited to, V, Ga, Ni, Sc, Zr, Ca, Hf, Sr, or combinations thereof. In certain
aspects, the alloy
composition comprises only unavoidable impurities. In certain aspects, the
remaining
percentage of the alloy is aluminum. All expressed in wt. %.
Alloy Properties
In certain embodiments, the aluminum alloys of the present invention display
one or more of
the following properties: very low earing (maximum mean earing level of 3 A);
high recycled
content (e.g., at least 60 %, 65 %, 70 %, 75 %, 80 %, 82 % or 85 A); yield
strength 25-36
ksi; excellent die cleaning performance which allows the application of very
low die striping
pressure; excellent formability which allows extensive neck shaping
progression without
fracture; excellent surface finished in the final bottles with no visible
markings; excellent
coating adhesion; high strength to meet the typical axial load (>300 lbs) and
dome reversal
pressure (>90 psi); overall scrap rate of the bottle making process can be as
low as less than 1
%.
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In certain embodiments, the substructure of the aluminum alloy coil made by
this
method has a geometrically necessary boundary (GNB)-free substructure. In
certain
embodiments, the substructure has a GNB-containing substructure with an
average GNB
spacing larger than 10 microns. In certain embodiments, the substructure
aluminum alloy
coil made by this method has a GNB-containing substructure with average GNB
spacing
larger than 300 nm (e.g., FIG. 1), average GNB spacing larger than 2.5 1.tm
(FIG. 2), average
GNB spacing larger than 81.tm (e.g., FIG. 3), or a GNB-free substructure
(e.g., FIG. 4).
In certain embodiments, the alloy sheet has very low earing. In certain
embodiments,
the earing balance from the edge, sides, and center (over the coil width) is
less than 1.5 %
(e.g., less than 1.25 %, less than 1 %). In certain embodiments, the mean
earing is less than 4
%. For example, the mean earing is less than 3.75 %, less than 3.5 %, less
than 3.25 %, less
than 3 %, less than 2.75 %, or less than 2.5 %.
In certain embodiments, the alloy sheet has high recycled content.
Methods ofMaking the Alloy
In certain aspects, the disclosed alloy composition is a product of a
disclosed method.
Without intending to limit the invention, aluminum alloy properties are
partially determined
by the formation of microstructures during the alloy's preparation. In certain
aspects, the
method of preparation for an alloy composition may influence or even determine
whether the
alloy will have properties adequate for a desired application.
In one aspect, the invention sets forth a method of making an aluminum alloy
described herein. Typically, can body stocks are provided to the customer in
the H19 temper.
For aluminum bottle application, the typical H19 temper does not work well as
H19 alloys
are too brittle. In one aspect, to meet the high formability requirement for
the shaping of
aluminum bottles, an inventive alloy must be processed in a different way, by
direct chill
(DC) casting, homogenizing, hot rolling, cold rolling, recrystallization
annealing, cold
rolling, and stabilization annealing.
In one embodiment, the method of making an aluminum alloy as described herein
comprises the sequential steps of:
DC casting;
Homogenizing;
Hot rolling;
Cold rolling (60-90 % thickness reduction);
Optionally recrystallization annealing (290-500 C/0.5-4 hrs);
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Cold rolling (15-30 % reduction);
Stabilization annealing (100-300 C/0.5-4 hrs).
In another embodiment, the method of making the aluminum alloy as described
herein
comprises the sequential steps of:
DC casting;
Homogenizing;
Hot rolling;
Cold rolling (60-90 % thickness reduction);
Optionally recrystallization annealing (300-450 C/1-2 hrs);
Cold rolling (15-30 % reduction); and,
Stabilization annealing (120-250 C/1-2 hrs).
In another embodiment, the method of making an aluminum alloy as described
herein
comprises direct chill casting an aluminum ingot; homogenizing the ingot; hot
rolling the
homogenized ingot to form a hot rolled product; cold rolling the hot rolled
product in a first
cold rolling step to produce a first cold rolled product, wherein the first
cold rolling step
produces an about 60-90 % thickness reduction. In certain embodiments the
method further
comprises cold rolling the first cold rolled product in a second cold rolling
step to produce a
second cold rolled product, wherein the second cold rolling step produces an
about 15-30 %
thickness reduction.
In certain embodiments having two cold rolling steps, the method further
comprises
recrystallization annealing the first cold rolled product, wherein the
recrystallization
annealing is at a metal temperature from about 290-500 C for about 0.5-4 hrs.
In certain
embodiments, the recrystallization annealing is at a metal temperature from
about 300-450
C. In certain embodiments, the recrystallization annealing is for about 1-2
hrs.
In certain embodiments having one or two cold rolling steps, the method
further
comprises stabilization annealing of the first cold rolled product if one cold
rolling step is
used or stabilization annealing of the second cold rolled product if two cold
rolling steps are
used, wherein the stabilization annealing is at a metal temperature from about
100-300 C for
about 0.5-4 hrs. In certain embodiments, the stabilization annealing is at a
metal temperature
of from about 120-250 C. In certain embodiments, the stabilization annealing
is for about
1-2 hrs.
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In certain embodiments where the alloy has a composition including about 0.25-
0.35
wt. % Si, about 0.44-0.56 wt. % Fe, about 0.09-0.160 wt. % Cu, about 0.78-0.94
wt. % Mn,
about 0.90-1.1 wt. % Mg, about 0.000-0.050 wt. % Cr, about 0.000-0.250 wt. %
Zn, about 0
.000-0.050 wt. % Ti, and up to 0.15 wt. % impurities, with the remainder Al,
the method of
making an aluminum alloy as described herein comprises direct chill casting an
aluminum
ingot; homogenizing the ingot; hot rolling the ingot to form a hot rolled
product; cold rolling
the hot rolled product to form a cold rolled product, wherein the cold rolling
produces an
about 60-90 % thickness reduction; and stabilization annealing of the cold
rolled product,
wherein the stabilization annealing is at a metal temperature from about 100-
300 C for
about 0.5-4 hrs. In certain embodiments the stabilization annealing is at a
metal temperature
of 120-250 C. In certain embodiments the stabilization annealing is for about
1-2 hrs.
In certain other embodiments where the alloy has a composition including about
0.12-0.28 wt. % Si, about 0.32-0.52 wt. % Fe, about 0.09-0.16 wt. % Cu, about
0.78-0.96
wt. % Mn, about 0.90-1.10 wt. % Mg, about 0.000-0.050 wt. % Cr, about 0.000-
0.250 wt. %
Zn, about 0.000-0.050 wt. % Ti, and up to 0.15 wt. % impurities, with the
remainder Al, the
method of making an aluminum alloy as described herein comprises direct chill
casting an
aluminum ingot; homogenizing the ingot; hot rolling the ingot to form a hot
rolled product;
cold rolling the hot rolled product in a first cold rolling step, wherein the
cold rolling
produces an about 60-90 % thickness reduction in the hot rolled product;
recrystallization
annealing of the cold rolled product, wherein the recrystallization annealing
is at a metal
temperature from about 290-500 C for about 0.5-4 hrs; cold rolling the
annealed product in
a second cold rolling step to produce a second cold rolled product, wherein
the second cold
rolling step produces an about 15-30 % thickness reduction in the annealed
product; and
stabilization annealing of the cold rolled product, wherein the stabilization
annealing is at a
metal temperature from about 100-300 C for about 0.5-4 hrs. In certain
embodiments, the
recrystallization annealing is at a metal temperature from about 300 to 450
C. In certain
embodiments, the recrystallization annealing is for about 1-2 hrs. In certain
embodiments the
stabilization annealing is at a metal temperature of 120-250 C. In certain
embodiments the
stabilization annealing is for about 1-2 hrs.
In other embodiments where the alloy has a composition including 0.12-0.28 wt.
%
Si, about 0.32-0.52 wt. % Fe, about 0.09-0.16 wt. % Cu, about 0.78-0.96 wt. %
Mn, about
0.90-1.10 wt. % Mg, about 0.000-0.050 wt. % Cr, about 0.000-0.250 wt. % Zn,
about
0.000-0.050 wt. % Ti, and up to 0.15 wt. % impurities, with the remainder Al,
the method of
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making an aluminum alloy as described herein comprises direct chill casting an
aluminum
ingot; homogenizing the ingot; hot rolling the ingot to form a hot rolled
product; cold rolling
the hot rolled product in a first cold rolling step to form a first cold
rolled product, wherein
the first cold rolling step produces an about 60-90 % thickness reduction in
the hot rolled
product; cold rolling the first cold rolled product in a second cold rolling
step, wherein the
second cold rolling step produces an about 15-30 % thickness reduction in the
product; and
stabilization annealing of the second cold rolled product, wherein the
stabilization annealing
is at a metal temperature from about 100-300 C for about 0.5-4 hrs. In
certain
embodiments, the stabilization annealing is at a metal temperature from about
120-250 C.
In certain embodiments, the stabilization annealing is for about 1-2 hrs.
The final temper of the alloys could be either H2x (without interannealing) or
H3x or
Hlx (with interannealing). The combination of rolling reduction gives
optimized earing and
excellent performance in the bodymaker. The stabilization annealing cycle was
designed to
induce specific working hardening characteristics and formability in the
alloys allowing
extensive neck shaping without fracture.
Casting
The alloys described herein can be cast into ingots using a direct chill (DC)
process.
The DC casting process is performed according to standards commonly used in
the aluminum
industry as known to one of skill in the art. Optionally, the casting process
can include a
continuous casting process. The continuous casting may include, but are not
limited to, twin
roll casters, twin belt casters, and block casters. In some embodiments, to
achieve the desired
microstructure, mechanical properties, and physical properties of the
products, the alloys are
not processed using continuous casting methods.
The cast ingot can then be subjected to further processing steps to form a
metal sheet.
In some embodiments, the further processing steps include subjecting a metal
ingot to a
homogenization cycle, a hot rolling step, a cold rolling step, an optional
recrystallization
annealing step, a second cold rolling step, and a stabilization annealing
step.
Homogenization
The homogenization step can involve a one-step homogenization or a two-step
homogenization. In some embodiments of the homogenization step, a one-step
homogenization is performed in which an ingot prepared from the alloy
compositions
described herein is heated to attain a peak metal temperature (PMT). The ingot
is then
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allowed to soak (i.e., held at the indicated temperature) for a period of time
during the first
stage.
In some embodiments of the homogenization step, a two-step homogenization is
performed where an ingot prepared from an alloy composition described herein
is heated to
attain a first temperature and then allowed to soak for a period of time In
the second stage,
the ingot can be cooled to a temperature lower than the temperature used in
the first stage and
then allowed to soak for a period of time during the second stage.
Hot Rolling
Following the homogenization, a hot rolling process can be performed. In some
embodiments, the ingots can be hot rolled to an 5 mm thick gauge or less. For
example, the
ingots can be hot rolled to a 4 mm thick gauge or less, 3 mm thick gauge or
less, 2 mm thick
gauge or less, or 1 mm thick gauge or less.
In some embodiments, to obtain an appropriate balance of texture in the final
materials, the hot rolling speed and temperature can be controlled such that
full
recrystallization of the hot rolled materials is achieved during coiling at
the exit of the tandem
mill.
Cold Rolling
In some embodiments, the hot rolled products can then be cold rolled to a
final gauge
thickness. In some embodiments, a first cold rolling step produces a reduction
in thickness of
from about 60-90 % (e.g. about 50-80 %, about 60-70 %, about 50-90 %, or about
60-80
%). For example, the first cold rolling step produces a reduction in thickness
of about 65 %,
about 70 %, about 75 %, about 80 %, about 85 %, or about 90 %. In some
embodiments, a
second cold rolling step produces a further reduction in thickness of from
about 15-30 %
(e.g., from about 20-25%, about 15-25%, about 15-20%, about 20-30%, or about
25-30 %).
For example, the second cold rolling step produces a further reduction in
thickness of about
15%, 20%, 25%, or 30%.
Annealing
In some embodiments, an annealing step is a recrystallization annealing (e.g.,
after the
initial cold rolling). In one embodiment, the recrystallization annealing is
at a metal
temperature from about 290-500 C for about 0.5-4 hrs. In one embodiment, the
recrystallization annealing is at a metal temperature from about 300-450 C.
In one
embodiment, the recrystallization is for about 1-2 hrs.
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The recrystallization annealing step can include heating the alloy from room
temperature to a temperature from about 290 C to about 500 C (e.g., from
about 300 C to
about 450 C, from about 325 C to about 425 C, from about 300 C to about
400 C, from
about 400 C to about 500 C, from about 330 C to about 470 C, from about
375 C to
about 450 C, or from about 450 C to about 500 C).
In certain aspects, an annealing step is stabilization annealing (e.g., after
the final cold
rolling). In one embodiment, the stabilization annealing is at a metal
temperature from about
100-300 C for about 0.5-4 hrs. In one embodiment, the stabilization annealing
is at a metal
temperature from about 120-250 C for about 1-2 hrs.
The stabilization annealing step can include heating the alloy from room
temperature
to a temperature from about 100 C to about 300 C (e.g., from about 120 C to
about 250 C,
from about 125 C to about 200 C, from about 200 C to about 300 C, from
about 150 C to
about 275 C, from about 225 C to about 300 C, or from about 100 C to about
175 C).
Methods of Preparing Highly Shaped Metal Objects
The methods described herein can be used to prepare highly shaped metal
objects,
such as aluminum cans or bottles. The cold rolled sheets described above can
be subjected to
a series of conventional can and bottle making processes to produce preforms.
The preforms
can then be annealed to form annealed preforms. Optionally, the preforms are
prepared from
the aluminum alloys using a drawing and wall ironing (DWI) process and the
cans and bottles
are made according to other shaping processes as known to those of ordinary
skill in the art.
The shaped aluminum bottle of the present invention may be used for beverages
including but not limited to soft drinks, water, beer, energy drinks and other
beverages.
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