Note: Descriptions are shown in the official language in which they were submitted.
WO 2018/226681
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ALUMINUM ALLOY ARTICLE HAVING LOW TEXTURE AND METHODS OF
MAKING THE SAME
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S. Provisional
Application
No. 62/515,714, filed on June 6,2017.
TECHNICAL FIELD
[0002] The present disclosure relates to metallurgy generally and more
specifically to metal
manufacturing. In certain aspects, the disclosure provides rolled aluminum
alloy articles
having a rolled surface having low texture (e.g., rectystallization texture).
In certain aspects,
the disclosure also provides methods of making such articles. In certain other
aspects, the
disclosure provides various end uses of such articles, such as in automotive,
transportation,
electronics, and industrial applications.
BACKGROUND
[0003] Aluminum alloy articles are desirable for use in a number of different
applications,
such as those where strength and durability are especially desirable. For
example, aluminum
alloys are commonly used for automotive structural applications in place of
steel. Because
aluminum alloys are generally about 2.8 times less dense than steel, the use
of such materials
reduces the weight of the vehicle and allows for substantial improvements in
its fuel
economy. Even so, the use of currently available aluminum alloys in automotive
and other
applications poses certain challenges.
100041 One such challenge relates to the emergence of recrystallization
texture during the
processing (e.g., rolling) of the aluminum alloy article, which leads to a
high degree of
anisotropy on the surface of the article. Thus, aluminum alloy rolled articles
(e.g., aluminum
alloy plates, aluminum alloy shates, and aluminum alloy sheets) can have
significant amounts
of recrystalfization texture that develops during the course of processing.
SUMMARY
[0005] Texturing of aluminum alloy rolled articles can modify the mechanical,
strength.
and forming properties. Thus, it may be desirable to provide an aluminum alloy
rolled article
having a surface that is nearly isotropic and thus, possessing nearly uniform
surface
1.
Date Recue/Date Received 2021-06-30
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properties. The present disclosure provides aluminum articles with surfaces,
or portions
thereof, that are substantially free of recrystallization texture, as well as
methods for making
and using such articles.
100061 The term embodiment and like terms are intended to refer broadly to all
of the
subject matter of this disclosure and the claims below. Statements containing
these terms
should be understood not to limit the subject matter described herein or to
limit the meaning
or scope of the claims below. Embodiments of the present disclosure covered
herein are
defined by the claims below, not this summary. This summary is a high-level
overview of
various aspects of the disclosure and introduces some of the concepts that are
further
described in the Detailed Description section below. This summary is not
intended to
identify key or essential features of the claimed subject matter, nor is it
intended to be used in
isolation to determine the scope of the claimed subject matter. The subject
matter should be
understood by reference to appropriate portions of the entire specification of
this disclosure,
any or all drawings and each claim.
100071 Embodiments of the present disclosure include an aluminum ahoy rolled
article
comprising a rolled surface, such as a rolled surface that comprises a first
surface portion that
is substantially free of recrystallization texture. In some non-limiting
examples, the first
surface portion can have an isotropic texture, such as an isotropic texture
that comprises a
plurality of texture components. As examples, different texture components may
comprise
less than or about 1 volume percent (vol. %) of the first surface portion. In
some aspects, the
plurality of texture components comprise surface texture components selected
from the group
consisting of a cube component, a goss component, a brass component, an S
component, and
a copper component. For example, in one embodiment, an aluminum alloy rolled
article
comprises a rolled surface with at least a portion that is free or
substantially free of
recrystallization texture and includes less than or about 1 volume percent
(i.e., between 0 and
1 volume percent) of a cube texture component, a goss texture component, a
brass texture
component, an S texture component, and a copper texture component.
100081 Surfaces having significant amounts of cube or other texture
components, in
embodiments, may correspond to surfaces that do not have an isotropic texture.
Stated
another way, surfaces including significant amounts of cube or other texture
components may
exhibit Langford coefficients (R-value) that are lower in a direction diagonal
from a
longitudinal direction (rolling direction) of the surface than those along the
longitudinal
direction or along a transverse direction (perpendicular to the rolling
direction). By
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generating an aluminum alloy rolled article with low amounts of surface
texture or with
randomized surface texturing, the articles can exhibit isotropic properties in
which the
Langford coefficients do not significantly vary as a function of angle from
the longitudinal
direction.
[0009] The first surface portion optionally has one or more surface texture
ratios between
0.80 and 1.25. In embodiments, a surface texture ratio corresponds to a
relationship between
volume percentages of a first surface texture and a second surface texture. In
some non-
limiting examples, the first surface portion has a cube component to brass
component ratio of
from 0.80 to 1.25, a cube component to goss component ratio of from 0.80 to
1.25, a cube
component to S component ratio of from 0.80 to 1.25, a cube component to
copper
component ratio of from 0.80 to 1.25, a goss component to brass component
ratio of from
0.80 to 1.25, a goss component to S component ratio of from 0.80 to 1.25, a
goss component
to copper component ratio of from 0.80 to 1.25, a brass component to S
component ratio of
from 0.80 to 1.25, a brass component to copper component ratio of from 0.80 to
1.25, an S
component to copper component ratio of from 0.80 to 1.25, a cube component to
goss
component to brass component ratio of from 0.80 to 1.25, a cube component to
goss
component to S component ratio of from 0.80 to 1.25, a cube component to goss
component
to copper component ratio of from 0.80 to 1.25, a goss component to brass
component to S
component ratio of from 0.80 to 1.25, a goss component to brass component to
copper
component ratio of from 0.80 to 1.25, a brass component to S component to
copper
component ratio of from 0.80 to 1.25, a cube component to goss component to
brass
component to S component ratio of from 0.80 to 1.25, a cube component to goss
component
to brass component to copper component ratio of from 0.80 to 1.25, a goss
component to
brass component to S component to copper component ratio of from 0.80 to 1.25.
or a cube
component to goss component to brass component to S component to copper
component ratio
of from 0.80 to 1.25. By controlling the amounts and ratios of different
texture components,
the aluminum rolled article may exhibit more isotropic properties.
[0010] In some non-limiting examples, the aluminum alloy rolled article can
have any
suitable width or length. Optionally, the alloy of the aluminum alloy rolled
article is a 5voc
aluminum alloy or a &Dix aluminum alloy. In some further examples, the
aluminum alloy
rolled article can be produced without cold rolling (i.e., hot rolled to a
final gauge). Stated
another way, the aluminum alloy rolled article may optionally be formed by a
process that
does not use cold rolling of the article to a fmal gauge or thickness. In some
non-limiting
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examples, the aluminum alloy rolled article described herein can be formed by
a process that
comprises providing a molten aluminum alloy composition, continuously casting
the molten
aluminum alloy composition to form an aluminum alloy cast product,
homogenizing the
aluminum alloy cast product to form a homogenized aluminum alloy cast product,
and rolling
the homogenized aluminum alloy cast product to form the aluminum alloy rolled
article
having a thickness of no more than 7 inm, such as between 0.01 mm and 7 mm,
between 0.01
mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm, between 0.01
mm
and 3 mm, or between 0.01 mm and 2 mm. Advantageously, the rolling may be
carried out at
a temperature of no less than 300 C, such as between 300 C and 550 C.
Rolling at
elevated temperatures may be useful, in embodiments, for preventing or
reducing
recrystallization and associated texturing of the aluminum alloy rolled
article.
NOM In some non-limiting examples, a method for making an aluminum alloy
rolled
article comprises providing a molten aluminum alloy composition, continuously
casting the
molten aluminum alloy composition to form an aluminum alloy cast product,
homogenizing
the aluminum alloy cast product to form a homogenized aluminum alloy cast
product, and
rolling the homogenized aluminum alloy cast product to form an aluminum alloy
rolled
article having a thickness of no more than 7 nun, such as between 0.01 mm and
7 mm,
between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm,
between 0.01 mm and 3 mm, or between 0.01 mm and 2 min, wherein the rolling is
carried
out at a temperature of no less than 300 C, such as between 300 C and 550
C. Following
the rolling, the rolled aluminum alloy rolled article can optionally be
subjected to quenching.
In some examples, direct chill casting is not utilized. In some examples, the
aluminum alloy
rolled article is rolled to a final thickness during the rolling and a
subsequent cold rolling
process is not used to achieve the final thickness of the aluminum alloy
rolled article.
100121 Optionally, homogenizing the aluminum alloy cast product includes
controlling a
homogenization temperature of the aluminum alloy cast product, such as after
exiting from a
continuous caster. Optionally, the homogenization temperature is between 400
C and 600
C, between 450 C and 600 C, between 400 C and 500 C, or between 500 C and
600 C.
In some examples, the aluminum alloy cast product is not cooled to below 400
C before the
homogenizing (i.e., between the casting and the homogenizing). In other
examples, however,
the aluminum alloy cast product may be cooled to below 400 C before the
homogenizing
(i.e., between the casting and the homogenizing).
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100131 Optionally, rolling the homogenized aluminum alloy cast product
includes
controlling a rolling temperature during rolling. For example, a starting
temperature of the
rolling is optionally between 400 C and 550 C. Optionally, an exit or
finishing temperature
of the rolling is between 300 C and 500 C. In some examples, rolling the
homogenized
aluminum alloy cast product includes maintaining the temperature at or above a
recrystallization temperature of the homogenized aluminum alloy.
100141 In some non-limiting examples, provided herein is an aluminum alloy
rolled article,
which is formed by a process comprising providing a molten aluminum alloy
composition,
continuously casting the molten aluminum alloy composition to form an aluminum
alloy cast
product, homogenizing the aluminum alloy cast product to form a homogenized
aluminum
alloy cast product, and rolling the homogenized aluminum alloy cast product to
form the
aluminum alloy rolled article having a thickness of no more than 7 mm, such as
between 0.01
mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01
mm
and 4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm, with the
rolling
carried out at a temperature of no less than 300 C, such as between 300 C
and 550 C. In
some non-limiting examples, the process does not comprise direct chill
casting. In some
further non-limiting examples, the continuously casting comprises using or use
of twin-belt
continuous casting. In some further non-limiting examples, the process does
not comprise
cold rolling.
100151 In some aspects, the aluminum alloy rolled article comprises a first
surface portion,
such as a first surface portion that is substantially free of
recrystallization texture. Optionally,
the first surface portion has an isotropic texture, such as an isotropic
texture that comprises a
plurality of texture components. For example, each texture component of the
plurality of
texture components may optionally comprise less than 1 volume percent of the
first surface
portion. In some examples, the aluminum alloy rolled article may have an
angularly uniform
(isotropic) Langford coefficient (R-value), such as an R-value that does not
vary appreciably
(e.g., less than 10%, less than 5%, or less than 1%) along an angle relative
to the rolling
direction. For example, R-values for an angularly uniform rolled aluminum
article may
advantageously vary between 0% and 10% (e.g., 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%,
8%,
9%, or 10%) at directions parallel to the rolling direction (longitudinal),
perpendicular to the
rolling direction (transverse), and at directions between longitudinal and
transverse directions
(diagonal).
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100161 In some non-limiting examples, provided herein is an aluminum alloy
article of
manufacture. The aluminum alloy article of manufacture can be an automotive
body part
(e.g., a structural part or an outer panel). The aluminum alloy article of
manufacture can be
an electronics device housing, an aerospace body part, a transportation body
part, or a
container part (e.g., a storage tank or an aluminum can). Aluminum alloy
articles of
manufacture may optionally be formed from an aluminum alloy rolled article
having a
surface five or substantially free of recrystallization texture, such as by a
technique involving
subjecting an aluminum alloy rolled article having a surface free or
substantially free of
recrystallization texture to a stamping, drawing, or other forming process.
BRIEF DESCRIPTION OF THE DRAWINGS
100171 The specification makes reference to the following appended figures, in
which use
of like reference numerals in different figures is intended to illustrate like
or analogous
components.
100181 FIG. 1 provides a schematic overview of a method of and system for
making an
aluminum alloy rolled article according to certain aspects of the present
disclosure.
100191 FIG. 2 is a graph comparing cube texture component to brass texture
component of
aluminum alloys produced according to certain aspects of the present
disclosure.
100201 FIG. 3 is a graph for AA6451 alloys comparing cube texture component,
goss
texture component, brass texture component, S texture component and copper
texture
component of aluminum alloys produced according to certain aspects of the
present
disclosure.
100211 FIG. 4 is a graph for AA6111 alloys comparing cube texture component,
goss
texture component, brass texture component. S texture component and copper
texture
component of aluminum alloys produced according to certain aspects of the
present
disclosure.
100221 FIG. 5 is a graph for AA5754 alloys comparing cube texture component,
goss
texture component, brass texture component, S texture component and copper
texture
component of aluminum alloys produced according to certain aspects of the
present
disclosure.
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DETAILED DESCRIPTION
[00231 Certain aspects and features of the present disclosure relate to
aluminum alloy
articles having isotropic surface textures. Aluminum alloy articles having
isotropic surface
textures can further have isotropic mechanical properties, providing highly
formable
aluminum alloy articles. Further aspects and features of the present
disclosure relate to
methods to produce aluminum alloy articles having isotropic surface textures.
Still further
aspects and features of the present disclosure include aluminum alloy rolled
articles having
isotropic surface textures.
Definitions and Descriptions
10024J 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.
100251 In this description, reference is made to alloys identified by aluminum
industry
designations, such as "series" or "6xxx." For an understanding of the number
designation
system most commonly used in naming and identifying aluminum and its alloys,
see
"International Alloy Designations and Chemical Composition Limits for Wrought
Aluminum
and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association
Alloy
Designations and Chemical Compositions Limits for Aluminum Alloys in the Form
of
Castings and Ingot," both published by The Aluminum Association.
100261 Aluminum alloys may described in terms of their elemental composition
in weight
percentage (wt. '?/o) based on the total weight of the alloy. In certain
examples of each alloy,
the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of the
impurities.
[0027I All ranges disclosed herein are to be understood to encompass any and
all subranges
subsumed therein. For example, a stated range of "1 to 10" should be
considered to include
any and all subranges between (and inclusive of) the minimum value of 1 and
the maximum
value of 10; that is, all subranges beginning with a minimum value of 1 or
more, e.g. 1 to 6.1,
and ending with a maximum value of 10 or less, e.g., 5.5 to 10.
[00281 As used herein, the meaning of -a," "an," or 'The" includes singular
and plural
references unless the context clearly dictates otherwise.
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100291 As used herein, a plate generally has a thickness greater than about
15 mm. For
example, a plate may refer to an aluminum or aluminum alloy product or article
having a
thickness of greater than or about 15 mm, greater than or about 20 mm, greater
than or about
25 mm, greater than or about 30 mm, greater than or about 35 mm, greater than
or about 40
mm, greater than or about 45 mm, greater than or about 50 mm, or greater than
or about 100
mm.
100301 As used herein, a shate (also referred to as a sheet plate)
generally has a thickness
of from about 4 mm to about 15 mm. For example, a shate may have a thickness
of about 4
mm. about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm,
about
Ii mm. about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
100311 As used herein, a sheet generally refers to an aluminum (or aluminum
alloy) cast
product or article having a thickness of less than about 4 mm. For example, a
sheet may have
a thickness of less than about 4 mm, less than about 3 mm, less than about 2
mm, less than
about 1 mm, less than about 0.5 mm, less than about 0.3 mm (e.g., about 0.2
nun), or between
0.2 nun and 4 min.
100321 Reference may be is made in this application to alloy temper or
condition. For an
understanding of the alloy temper descriptions most commonly used, see
"American National
Standards (ANSI) H35 on Alloy and Temper Designation Systems." An F condition
or
temper refers to an aluminum alloy as fabricated. An Hxx condition or temper,
also referred
to herein as an H temper, refers to a non-heat treatable aluminum alloy after
cold rolling with
or without thermal treatment (e.g., annealing). Suitable H tempers include
HX1, HX2, HX3
HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A Ti condition or temper refers to an
aluminum alloy cooled from hot working and naturally aged (e.g., at room
temperature). A
T2 condition or temper refers to an aluminum alloy cooled from hot working,
cold worked
and naturally aged. A T3 condition or temper refers to an aluminum alloy
solution heat
treated, cold worked, and naturally aged. A T4 condition or temper refers to
an aluminum
alloy solution heat treated and naturally aged. A T5 condition or temper
refers to an
altuninum alloy cooled from hot working and artificially aged (at elevated
temperatures). A
T6 condition or temper refers to an aluminum alloy solution heat treated and
artificially aged.
A T7 condition or temper refers to an aluminum alloy solution heat treated and
artificially
overaged. A T8x condition or temper refers to an aluminum alloy solution heat
treated, cold
worked, and artificially aged. A 19 condition or temper refers to an aluminum
alloy solution
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heat treated, artificially aged, and cold worked. A W condition or temper
refers to an
aluminum alloy after solution heat treatment.
[0033] As used herein, the term "substantially free of surface texture" refers
to a
characteristic of all or a portion of a surface of a prepared metal plate,
shate, or sheet wherein
no one of a cube texture component, a goss texture component, a brass texture
component, an
S texture component, or a copper texture component is a predominant texture
component
found within the portion of the surface of the prepared metal plate, shate or
sheet. For
example, a surface substantially free of surface texture may have low volume
or areal
percentages of a cube texture component, a goss texture component, a brass
texture
component, an S texture component, and a copper texture component, such as
less than or
about 1 volume percent or less than or about 1 areal percent.
[0034] As used herein, the term "uniform thinning" refers to a rolling
deformation wherein
a thickness of a prepared metal plate, shate, or sheet is decreased during
rolling such that the
thickness of a first portion of the prepared metal plate, shate, or sheet
remains within 2% of
a thickness of any other portion of the prepared metal plate, shate, or sheet.
In some cases,
uniform thinning may refer to a uniformity of the reduction of a thickness of
a prepared metal
plate, shate, or sheet upon being subjected to a tensile stress along a
different directions (e.g.,
a longitudinal direction (rolling direction), a transverse direction
(perpendicular to the rolling
direction), or a diagonal direction (direction between the transverse and
longitudinal
directions). Optionally, a material that undergoes uniform thinning may have a
Langford
coefficient (R-value) that does not substantially vary as a function of angle
(i.e., angle from
the rolling direction).
[0035] As used herein, terms such as "cast product," "cast metal product,"
"cast aluminum
product," "cast aluminum alloy product," "aluminum alloy cast product," and
the like are
interchangeable and may refer to a product produced by direct chill casting
(including direct
chill co-casting), semi-continuous casting, continuous casting (including, for
example, by use
of a twin belt caster, a twin roll caster, a block caster, or any other
continuous caster),
electromagnetic casting, hot top casting. or any other casting method.
Aluminum Alloy Rolled Articles
Aluminum Alloy Rolled Article Surface
[0036] In some non-limiting examples, an aluminum alloy rolled article having
a rolled
surface can have at least a first surface portion that has low volume
fractions of a cube texture
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component, a goss texture component, a brass texture component, an S texture
component,
and a copper texture component, such as volume fractions that are between 0%
and 1%, or
that is substantially free of recrystallization texture. In the context of the
present disclosure, a
surface portion that is substantially free of recrystallization texture refers
to a surface portion
that is uniform across an area defined as the surface portion, wherein no one
recrystallization
texture component is dominant. In some non-limiting examples, a surface
portion that has
low volume fractions of a cube texture component, a goss texture component, a
brass texture
component, an S texture component, and a copper texture component, such as
volume
fractions that are between 0% and 1%, or that is substantially free of
recrystallization texture
may refer to a surface portion in which recrystallization textures that
exhibit angularly
dependent Langford coefficients are present only in minor amounts such that
the overall
Langford coefficient of the surface portion is isotropic (i.e., not
substantially angularly
dependent or substantially angularly unifonn). In some non-limiting examples,
a surface
portion can have an isotropic texture, wherein the isotropic texture comprises
a plurality of
texture components, wherein each texture component comprises less than 1
volume percent
(vol. %) of the surface portion. In some aspects, the plurality of texture
components
comprise surface texture components selected from the group consisting of a
cube
component, a goss component, a brass component, an S component, and a copper
component.
100371 In some cases, the aluminum alloy rolled article described herein can
have an
isotropic surface texture described as a ratio between each texture component.
In some non-
limiting examples, a surface portion can have a ratio of the cube component to
the brass
component (and likewise, a ratio of the brass component to the cube component)
of from 0.80
to 1.25. For example, the surface portion can have a ratio of the cube
component to the brass
component of 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, or 1.25.
In some examples, the ratio of the cube component to the brass component can
be less than
1.00.
[00381 In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the goss component (and likewise, a ratio of the goss component
to the cube
component) of from 0.80 to 1.25. For example, the surface portion can have a
ratio of the
cube component to the goss component of 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,
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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, or 1.25. In some examples, the ratio of the cube
component to the goss
component can be less than 1.00.
100391 In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the S component (and likewise, a ratio of the S component to the
cube
component) of from 0.80 to 1.25. For example, the surface portion can have a
ratio of the
cube component to the S component of 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, or 1.25. In some examples, the ratio of the cube
component to the S
component can be less than 1.00.
100401 In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the copper component (and likewise, a ratio of the copper
component to the
cube component) of from 0.80 to 1.25. For example, the surface portion can
have a ratio of
the cube component to the copper component of 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, or 1.25. In some examples, the ratio of the cube
component to
the copper component can be less than 1.00.
100411 In some non-limiting examples, the surface portion can have a ratio of
the goss
component to the brass component of from 0.80 to 1.25. For example, the
surface portion
can have a ratio of the goss component to the brass component (and likewise, a
ratio of the
brass component to the goss component) of 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, or 1.25. In some examples, the ratio of the goss
component to
the brass component can be less than 1.00.
100421 In some non-limiting examples, the surface portion can have a ratio of
the goss
component to the S component (and likewise, a ratio of the S component to the
goss
component) of from 0.80 to 1.25. For example, the surface portion can have a
ratio of the
goss component to the S component of 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,
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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, or 1.25. In some examples, the ratio of the goss
component to the S
component can be less than 1.00.
[0043] In some non-limiting examples, the surface portion can have a ratio of
the goss
component to the copper component (and likewise, a ratio of the copper
component to the
goss component) of from 0.80 to 1.25. For example, the surface portion can
have a ratio of
the goss component to the copper component of 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, or 1.25. In some examples, the ratio of the goss
component to
the copper component can be less than 1.00.
[0044] In some non-limiting examples, the surface portion can have a ratio of
the brass
component to the S component (and likewise, a ratio of the S component to the
brass
component) of from 0.80 to 1.25. For example, the surface portion can have a
ratio of the
brass component to the S component of 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, or 1.25. In some examples, the ratio of the brass
component to the S
component can be less than 1.00.
[0045] In some non-limiting examples, the surface portion can have a ratio of
the brass
component to the copper component (and likewise, a ratio of the copper
component to the
brass component) of from 0.80 to 1.25. For example, the surface portion can
have a ratio of
the brass component to the copper component of 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, or 1.25. In some examples, the ratio of the
brass component to
the copper component can be less than 1.00.
[0046i In some non-limiting examples, the surface portion can have a ratio of
the S
component to the copper component (and likewise, a ratio of the copper
component to the S
component) of from 0.80 to 1.25. For example, the surface portion can have a
ratio of the S
component to the copper component of 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,
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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, or 1.25. In some examples, the ratio of the S
component to the copper
component can be less than 1.00.
100471 In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the goss component to the brass component (or any suitable ratio
including the
cube component, the goss component, and the brass component) of from 0.80 to
1.25. For
example, the surface portion can have a ratio of the cube component to the
goss component to
the brass component of 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, or 1.25. In some examples, the ratio of the cube component to the goss
component to
the brass component can be less than 1.00.
100481 In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the goss component to the S component (or any suitable ratio
including the
cube component, the goss component, and the S component) of from 0.80 to 1.25.
For
example, the surface portion can have a ratio of the cube component to the
goss component to
the S component of 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, or
1.25. In some examples, the ratio of the cube component to the goss component
to the S
component can be less than 1.00.
100491 In some non-limiting examples. the surface portion can have a ratio of
the cube
component to the goss component to the copper component (or any suitable ratio
including
the cube component, the goss component, and the copper component) of from 0.80
to 1.25.
For example, the surface portion can have a ratio of the cube component to the
goss
component to the copper component of 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, or 1.25. In some examples, the ratio of the cube
component to the goss
component to the copper component can be less than 1.00.
pm! In some non-limiting examples, the surface portion can have a ratio of
the goss
component to the brass component to the S component (or any suitable ratio
including the
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goss component, the brass component, and the S component) of from 0.80 to
1.25. For
example, the surface portion can have a ratio of the goss component to the
brass component
to the S component of 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, or 1.25. In some examples, the ratio of the goss component to the brass
component to
the S component can be less than 1.00.
[0051] In some non-limiting examples, the surface portion can have a ratio of
the goss
component to the brass component to the copper component (or any suitable
ratio including
the goss component, the brass component, and the copper component) of from
0.80 to 1.25.
For example, the surface portion can have a ratio of the goss component to the
brass
component to the copper component of 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, or 1.25. In some examples, the ratio of the goss
component to the
brass component to the copper component can be less than 1.00.
[0052] In some non-limiting examples, the surface portion can have a ratio of
the brass
component to the S component to the copper component (or any suitable ratio
including the
brass component, the S component, and the copper component) of from 0.80 to
1.25. For
example, the surface portion can have a ratio of the brass component to the S
component to
the copper component of 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, or 1.25. In some examples, the ratio of the brass component to the S
component to the
copper component can be less than 1.00.
[0053] In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the goss component to the brass component to the S component (or
any
suitable ratio including the cube component, the goss component, the brass
component, and
the S component) of from 0.80 to 1.25. For example, the surface portion can
have a ratio of
the cube component to the goss component to the brass component to the S
component of
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,
or 1.25. In some
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examples, the ratio of the cube component to the goss component to the brass
component to
the S component can be less than 1.00.
[0054] In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the goss component to the brass component to the copper component
(or any
suitable ratio including the cube component, the goss component, the brass
component, and
the copper component) of from 0.80 to 1.25. For example, the surface portion
can have a
ratio of the cube component to the goss component to the brass component to
the copper
component of 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, or 1.25.
In some examples, the ratio of the cube component to the goss component to the
brass
component to the copper component can be less than 1.00.
100551 In some non-limiting examples, the surface portion can have a ratio of
the goss
component to the brass component to the S component to the copper component
(or any
suitable ratio including the goss component, the brass component, the S
component, and the
copper component) of from 0.80 to 1.25. For example, the surface portion can
have a ratio of
the goss component to the brass component to the S component to the copper
component of
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,! 17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or
1.25. In some
examples, the ratio of the. goss component to the brass component to the S
component to the
copper component can be less than 1.00.
100561 In some non-limiting examples, the surface portion can have a ratio of
the cube
component to the goss component to the brass component to the S component to
the copper
component (or any suitable ratio including the cube component, the goss
component, the
brass component, the S component, and the copper component) of from 0.80 to
1.25. For
example, the surface portion can have a ratio of the cube component to the
goss component to
the brass component to the S component to the copper component of 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, or 1.25. In some
examples, the ratio of the
cube component to the goss component to the brass component to the S component
to the
copper component can be less than 1.00.
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100571 In some aspects, an aluminum alloy article having a portion that has
low volume
fractions of a cube texture component, a goss texture component, a brass
texture component,
an S texture component, and a copper texture component, such as volume
fractions that are
between 0% and 1%, or that is substantially free of recrystallization texture
(e.g., an isotropic
texture, or a texture-less surface) in any direction relative to a rolling
direction of the
aluminum alloy article (e.g., longitudinal, transverse or diagonal) can
provide an aluminum
alloy having isotropic mechanical properties in any direction relative to the
rolling direction
of the aluminum alloy article. For example, an aluminum alloy article having
isotropic
mechanical properties can provide an aluminum alloy article that does not
exhibit anisotropic
forming in, for example, the diagonal direction while exhibiting isotropic
forming in the
longitudinal and/or transverse direction.
100581 In some examples, comparative aluminum alloy articles may correspond to
an
aluminum alloy article that can be direct chill cast from a molten aluminum
alloy to form an
aluminum alloy ingot. The aluminum alloy ingot can then be homogenized and hot
rolled to
an intermediate gauge aluminum alloy plate. The intermediate gauge aluminum
alloy plate
can optionally further be cold rolled to a final gauge aluminum alloy article.
Comparative
aluminum alloy articles can have a plurality of surface portions having a
dominant texture
component. For example, a first surface portion can be dominated by a cube
texture and at
least a second surface portion can be dominated by a goss texture component.
Thus, the
diagonal direction relative to the rolling direction of the comparative
aluminum alloy article
can have an anisotropic recrystallization texture, wherein a first surface
portion can be
dominated by cube texture and at least a second surface portion can be
dominated by a goss
texture component. A lower amount of thinning during rolling in the diagonal
direction can
be caused by splitting surface portions (e.g., pulling the first surface
portion away from the at
least second surface portion) in the diagonal direction relative to the
rolling direction during
fonning. An exemplary aluminum alloy article, produced according to methods
described
below, can have an isotropic surface texture in any direction relative to the
rolling direction
and provide uniform thinning in any direction relative to the rolling
direction.
Aluminum Alloy Rolled Article Gauges and Compositions
100591 In some non-limiting examples, aluminum alloy rolled articles can be
produced in a
plate gauge, a shate gauge, or a sheet gauge, as described above. In some
aspects, the
aluminum alloy rolled article can be produced from a molten altuninum alloy.
The molten
aluminum alloy can be a 5xxx series aluminum alloy or a 6voc series aluminum
alloy.
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100601 Non-limiting exemplary AA5xxx series aluminum alloys include AA5005,
AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110,
AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A,
AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028,
AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349,
AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A,
AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154,
AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654,
AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A,
AA5456B, AA5556, AA5556A, AA555613, AA5556C, AA5257, A A5457, AA5557,
AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083,
AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186,
AA5087, AA5187, and AA5088.
100611 Non-limiting exemplary AA6xxx series aluminum alloys include AA6101,
AA6101A, AA6101B, AA6201, AA6201A, AA6401., AA6501, AA6002, AA6003, AA6103,
AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106,
AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111,
AA6012, AA601.2A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116,
AA6018õAA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026,
AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043,
AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156,
AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061,
AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463,
AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069,
AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6112, AA6091, and
AA6092.
Methods of Making
100621 An exemplary aluminum alloy rolled article can be formed by a process
that
includes providing a molten aluminum alloy composition, continuously casting
the molten
aluminum alloy composition to form an aluminum alloy cast product,
homogenizing the
aluminum alloy cast product to form a homogenized aluminum alloy cast product,
and hot
rolling the homogenized aluminum alloy cast product to form the aluminum alloy
rolled
article having a thickness of no more than 7 mm, such as between 0.01 mm and 7
mm,
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between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm,
between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm. The rolling can be
carried out
at a temperature of no less than 300 C. The exemplary aluminum alloy rolled
article can be
formed by a process that does not include cold rolling. Optionally, the
exemplary aluminum
alloy rolled article can be subjected to quenching after the rolling. FIG. 1
provides a
schematic example of a method and system of making an aluminum alloy rolled
article. In
embodiments, FIG. 1 provides an overview of a process referred to as a hot
roll to fmal gauge
and temper.
Continuous Casting
100631 The aluminum alloy products described herein can be cast using a
continuous
casting (CC) process. The continuous casting process can be performed, for
example, by way
of the use of twin belt casters, twin roll casters, or block casters.
100641 As illustrated in FIG. 1, in some examples, a method of making an
aluminum alloy
rolled article includes providing a molten aluminum alloy 105 and continuously
injecting the
molten metal from a molten metal injector into a continuous caster 110 to form
an aluminum
alloy cast product 115. The method also can include withdrawing the aluminum
alloy cast
product, such as a cast aluminum alloy sheet, plate, or shate, from an exit of
the continuous
caster.
Rolling
100651 The aluminum alloy cast product 115 can then be processed by any
suitable means.
Optionally, the processing steps can be used to prepare aluminum alloy rolled
articles. Such
processing steps include, but arc not limited to, homogenization, which may
occur as
illustrated in FIG. 1 at block 120, and hot rolling, which may occur as
illustrated in FIG. 1 at
section 125. In some non-limiting examples, as explained in more detail below,
a
continuously cast aluminum alloy product, such as a 6xxx series aluminum alloy
or a 5xxx
series aluminum alloy, can be hot rolled to a final gauge. The processing can
be performed
without a cold rolling step (i.e., the cast product can be rolled to a final
gauge without cold
rolling). In some cases, hot rolling a continuously cast aluminum alloy
product to a final
gauge can provide an isotropic recrystallization texture within a surface of
the aluminum
alloy rolled article thereby formed. In some further cases, hot rolling a
continuously cast
aluminum alloy product to a final gauge can improve formability by providing
an aluminum
alloy rolled article having isotropic mechanical properties.
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100661 Optionally, homogenization can be performed immediately after casting.
Optionally, the temperature of the aluminum alloy cast product 115 is not
permitted to fall
below 400 C between casting and homogenizing. The homogenization temperature
can be
between 400 C and 600 C, for example. In some examples, homogenization may
be useful
for maintaining a temperature of the cast alloy at a particular value or
between a range of
values for a duration of time, such as up to 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 hours in some
examples. In some
examples, homogenization may be useful for providing the cast alloy to a hot
rolling stage at
a particular starting temperature. After homogenization is performed at block
120, the
aluminum alloy cast product 115 may be referred to as a homogenized aluminum
alloy cast
product.
100671 Optionally, the hot rolling step can be performed immediately after
casting or
following homogenization. The hot rolling temperature can be at least 300 C,
such as
between 300 C and 550 C. For example, the hot rolling temperature can be at
least 300 C,
at least 310 C, at least 320 C, at least 330 C, at least 340 C, at least
350 C, at least 360
C, at least 370 C, at least 380 C, at least 390 C, at least 400 C, at
least 410 C, at least
420 C, at least 430 C, at least 440 C, at least 450 C, at least 460 C, at
least 470 C, at
least 480 C, at least 490 C, at least 500 C, at least 510 C, at least 520
C, at least 530 C,
at least 540 C, or up to 550 C. Optionally, the hot rolling temperature can
be or include the
recrystallization temperature of the aluminum alloy. The homogenized aluminum
alloy cast
product or aluminum alloy cast product entering into the hot rolling stage can
have a
temperature of between 400 C and 550 C, for example.
[0068] During the hot rolling step, the gauge of the aluminum alloy cast
product is reduced
in thickness. In some cases, the total amount of reduction of thickness during
hot rolling can
be at or less than 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%,
25%,
20%, or 15%. In some cases, the cast product can be a metal sheet wherein the
final gauge of
the rolled article is 7 mm or less, 6 mm or less, 5 mm or less, 4 mm or less,
3 mm or less, 2
mm or less, 1.9 mm or less, 1.8 mm or less, 1.7 mm or less, 1.6 mm or less,
1.5 mm or less,
1.4 nun or less, 1.3 mm or less, 1.2 mm or less, 1.1 min, 1.0 mm or less, 0.9
mm or less, 0.8
mm or less, 0.7 mm or less, 0.6 mm or less, 0.5 mm or less, 0.4 mm or less,
0.3 mm or less,
0.2 mm or less, or as small as 0.1 mm. Upon exiting the hot rolling stage, the
aluminum alloy
rolled article can have a temperature of between 300 C and 500 C, for
example.
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Optional Processing Steps
[00691 The method can optionally include a step of quenching the aluminum
alloy rolled
article after hot rolling, as illustrated at element 130 of FIG. 1. The
aluminum alloy rolled
article can be cooled to a temperature at or below about 300 C in the
quenching step, such as
to a temperature between 50 C and 300 'C. For example, the aluminum alloy
rolled article
can be cooled to a temperature at or below 290 C, at or below 280 C, at or
below 270 C, at
or below 260 C, at or below 250 C, at or below 240 C, at or below 230 C,
at or below 220
C, at or below 210 C, at or below 200 C, at or below 190 C, at or below 180
C, at or
below 170 C, at or below 160 C, at or below 150 C, at or below 140 C, at
or below 130
C, at or about 120 C, at or below 110 C, or at or below 100 C. The aluminum
alloy rolled
article can be quenched immediately after hot rolling or within a short period
of time
thereafter (e.g., within 10 hours or less, 9 hours or less, 8 hours or less, 7
hours or less, 6
hours or less, 5 hours or less, 4 hours or less, 3 hours or less, 2 hours or
less, 1 hour or less, or
30 minutes or less). The aluminum alloy rolled article can optionally be
coiled and stored
after hot rolling and/or quenching, as illustrated at element 135 of FIG. 1.
Methods of Use
Automotive and Transportation
10070] Aluminum alloy articles of manufacture produced from aluminum alloy
rolled
articles, such as sheets and shates, described herein can be used in
automotive applications
and other transportation applications, including aircraft and railway
applications. For
example, the aluminum alloy rolled articles can be used to prepare automotive
structural
parts, such as outer panels, inner panels, side panels, bumpers, side beams,
roof beams, cross
beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars),
inner hoods, outer
hoods, or trunk lid panels. The aluminum alloy rolled articles and methods
described herein
can also be used in aircraft or railway vehicle applications, to prepare, for
example, external
and internal panels.
Electronics
100711 The aluminum alloy rolled articles described herein can also be used in
electronics
applications. For example, the aluminum alloy rolled articles and methods
described herein
can be used to prepare housings for electronic devices, including mobile
phones and tablet
computers. In some examples, the altuninum alloy rolled articles can be used
to prepare
anodized quality sheets and materials.
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Containment
[00721 The aluminum alloy rolled articles described herein can be used in
container
applications, including aluminum can body stock and aluminum can end stock.
Mechanical Properties
100731 The aluminum alloy rolled articles described herein can have a surface
that has low
volume fractions of a cube texture component, a goss texture component, a
brass texture
component, an S texture component, and a copper texture component, such as
volume
fractions that are between 0% and 10/0, or that is substantially free of
recrystallization texture.
An alumimun alloy article having a surface of this nature (e.g., an isotropic
surface) can
provide an aluminum alloy article having isotropic mechanical properties
(e.g., mechanical
properties that can be uniform in any direction across the surface relative to
a rolling
direction of the aluminum alloy cast product). An aluminum alloy rolled
article having
isotropic mechanical properties can be subjected to forming processes that
demand a high
formability. In some non-limiting examples, the aluminum alloy rolled articles
described
herein can be subjected to complex forming processes. In some further
examples, the
altuninum alloy rolled articles described herein can be subjected to multi-
step forming
processes.
100741 Various advantages may be achieved using the aluminum alloy cast
products and
aluminum alloy rolled articles and methods of making aluminum alloy cast
products and
aluminum alloy rolled articles described herein. For example, as noted above,
the aluminum
alloy rolled articles may exhibit advantageous mechanical properties, such as
an isotropic
surface. Additionally, the aluminum alloy rolled articles may exhibit
isotropic thinning
properties when subjected to strain, meaning that the aluminum alloy rolled
articles may have
a tendency to thin during straining by an approximately equal amount in all
directions. This
property may provide a benefit in forming articles of manufacture using the
aluminum alloy
rolled articles described herein.
[00751 For example, conventionally cold-rolled aluminum may exhibit mechanical
anisotropy, meaning the mechanical properties of the cold-rolled aluminum are
not uniform
along different directions (e.g., rolling direction, transverse direction,
diagonal direction,
etc.). When cold-rolled aluminum is subjected to forming or drawing to
generate an article of
manufacture, the material may have a tendency to thin different amounts upon
being
subjected to strain along different directions. Depending on the shape and
specific form of
the article of manufacture, the article may thin significantly more in some
locations than in
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others. When subjected to sufficient strain and thinning along directions that
have a tendency
to thin much more than others (e.g., along a diagonal direction), the article
of manufacture
may break. fracture, or otherwise fail at these critical points or along these
critical directions.
[0076] Due to the isotropic mechanical properties, the presently described
aluminum alloy
cast products and aluminum alloy rolled articles overcome these and other
processing
difficulties. By having a surface that has low volume fractions of a cube
texture component.
a goss texture component, a brass texture component, an S texture component,
and a copper
texture component, such as volume fractions that are between 0% and 1%, or
that is
substantially free of recrystallization texture, the surface can exhibit
isotropic mechanical
properties, such as the Langford coefficient (R-value), such that forming an
article of
manufacture using the presently described aluminum alloy rolled articles does
not result in
the same failure along the above-described critical directions or at the above-
described
critical points.
[00771 The following examples will serve to further illustrate the present
invention without,
at the same time, however, constituting any limitation thereof. On the
contrary, it is to be
clearly understood that resort can be had to various embodiments,
modifications and
equivalents thereof which, after reading the description herein, can suggest
themselves to
those skilled in the art without departing from the spirit of the invention.
EXAMPLE A
[00781 Aluminum alloy samples were provided according to methods described
herein.
Alloys 6111, 6451, and 5754 were produced by exemplaty methods, including
continuous
casting, homogenization and hot rolling to a final gauge. Alloys 6451 and 5754
were further
produced by an optional method for comparison, including continuous casting,
homogenization and cold rolling to a final gauge. Alloys 6111, 6451, and 5754
were
produced according to comparative methods, including direct chill casting,
homogenization,
hot rolling, and cold rolling. The aluminum alloy samples were analyzed for
recrystallization
texture. FIG. 1 is a bar chart showing results of recrystallization texture
analysis. A cube
texture component (left histogram in each pair) and a brass texture component
(right
histogram in each pair) are shown form comparison. Texture component volume
fraction (%)
is shown for cube and brass texture components. Continuously cast alloys are
referred to
herein as "CC" and direct chill cast alloys are referred to herein as "DC."
Processing
methods are described in Table 1 below:
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____________________ Table 1 ¨ Processillg Methods
HRTGT Hot roll to final gauge and temper
HR+CR Hot roll and cold roll
CR Cold roll
HR Hot roll
100791 Hot roll to final gauge and temper indicates the exemplary method
described herein,
including continuous casting, homogenization, and hot rolling to a final
gauge, as shown in
FIG. 1. The exemplary method provided aluminum alloy rolled articles having a
uniform
distribution of texture components, as shown in FIGs. 2, 3, and 4 and
described below. The
comparative methods provided an aluminum alloy rolled article having an
anisotropic
recrystallization texture, wherein the surface was dominated by cube texture.
Isotropic
surface recrystallization texture was provided by the exemplary method
described herein.
100801 FIGs. 2, 3, and 4 are bar charts showing results of reciystallization
texture analysis.
A cube texture component (left histogram in each set), a goss texture
component (second
from the left histogram in each set), a brass texture component (center
histogram in each set),
an S texture component (fourth from the left histogram in each set) and a
copper texture
component (right histogram in each set) are shown for comparison. As evident
in FIGs. 2, 3,
and 4, the exemplary method provided aluminum alloy rolled articles having a
uniform
distribution of texture components, wherein no texture component was observed
having a
volume fraction greater than 1% within the surface of the aluminum alloy. The
comparative
methods provided an aluminum alloy rolled articles having an anisotropic
recrystallization
texture, wherein the surface was dominated by cube texture. Isotropic surface
recrystallization texture was provided by the exemplary method described
herein.
EXAMPLES 1-61
(0081j As used below, any reference to a series of examples is to be
understood as a
reference to each of those examples disjunctively (e.g., "examples 1-4" is to
be understood as
"examples 1, 2, 3, or 4").
100821 Example! is an aluminum alloy rolled article comprising a rolled
surface, wherein
the rolled surface comprises a first surface portion, comprising at least a
first surface portion,
and wherein the first surface portion is substantially free of
recrystallization texture or
wherein the first surface portion has volume fractions of a cube texture
component, a goss
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texture component, a brass texture component, an S texture component, and a
copper texture
component that are between 0% and 1%.
[0083] Example 2 is the aluminum alloy rolled article of example 1, wherein
the first
surface portion has an isotropic texture, wherein the isotropic texture
comprises a plurality of
texture components, wherein each texture component comprises less than 1
volume percent
of the first surface portion.
[0084] Example 3 is the aluminum alloy rolled article of example 2, wherein
the plurality
of texture components comprise surface texture components selected from the
group
consisting of a cube component, a goss component, a brass component, an S
component, and
a copper component.
[0085] Example 4 is the aluminum alloy rolled article of examples 1-3, wherein
the first
surface portion exhibits substantially uniform thinning during forming across
the first surface
portion in any direction relative to a rolling direction.
[0086] Example 5 is the aluminum alloy rolled article of examples 1-4, wherein
the first
surface portion has a cube component to brass component ratio of from 0.80 to
1.25.
[0087] Example 6 is the aluminum alloy rolled article of examples 1-5, wherein
the first
surface portion has a cube component to goss component ratio of from 0.80 to
1.25.
[0088] Example 7 is the aluminum alloy rolled article of examples 1-6, wherein
the first
surface portion has a cube component to S component ratio of from 0.80 to
1.25.
[0089] Example 8 is the aluminum alloy rolled article of examples 1-7, wherein
the first
surface portion has a cube component to copper component ratio of from 0.80 to
1.25.
[0090] Example 9 is the aluminum alloy rolled article of examples 1-8, wherein
the first
surface portion has a goss component to brass component ratio of from 0.80 to
1.25.
[0091] Example 10 is the aluminum alloy rolled article of examples 1-9,
wherein the first
surface portion has a goss component to S component ratio of from 0.80 to
1.25.
[0092] Example 11 is the aluminum alloy rolled article of examples 1-10,
wherein the first
surface portion has a goss component to copper component ratio of from 0.80 to
1.25.
[0093] Example 12 is the aluminum alloy rolled article of examples 1-11,
wherein the first
surface portion has a brass component to S component ratio of from 0.80 to
1.25.
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[0094] Example 13 is the aluminum alloy rolled article of examples 1-12,
wherein the first
surface portion has a brass component to copper component ratio of from 0.80
to 1.25.
100951 Example 14 is the aluminum alloy rolled article of examples 1-13,
wherein the first
surface portion has an S component to copper component ratio of from 0.80 to
1.25.
100961 Example 15 is the aluminum alloy rolled article of examples 1-14,
wherein the first
surface portion has a cube component to goss component to brass component
ratio of from
0.80 to 1.25.
[0097] Example 16 is the aluminum alloy rolled article of examples 1-15,
wherein the first
surface portion has a cube component to goss component to S component ratio of
from 0.80
to 1.25.
[0098] Example 17 is the aluminum alloy rolled article of examples 1-16,
wherein the first
surface portion has a cube component to goss component to copper component
ratio of from
0.80 to 1.25.
[0099] Example 18 is the aluminum alloy rolled article of examples 1-17,
wherein the first
surface portion has a goss component to brass component to S component ratio
of from 0.80
to 1.25.
[0100] Example 19 is the aluminum alloy rolled article of examples 1-18,
wherein the first
surface portion has a goss component to brass component to copper component
ratio of from
0.80 to 1.25.
101011 Example 20 is the aluminum alloy rolled article of examples 1-19,
wherein the first
surface portion has a brass component to S component to copper component ratio
of from
0.8010 125.
[0102] Example 21 is the aluminum alloy rolled article of examples 1-20,
wherein the first
surface portion has a cube component to goss component to brass component to S
component
ratio of from 0.80 to 1.25.
[0103] Example 22 is the aluminum alloy rolled article of examples 1-21,
wherein the first
surface portion has a cube component to goss component to brass component to
copper
component ratio of from 0.80 to 1.25.
[0104] Example 23 is the aluminum alloy rolled article of examples 1-22,
wherein the first
surface portion has a goss component to brass component to S component to
copper
component ratio of from 0.80 to 1.25.
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[0105] Example 24 is the aluminum alloy rolled article of examples 1-23,
wherein the first
surface portion has a cube component to goss component to brass component to S
component
to copper component ratio of from 0.80 to 1.25.
[0106] Example 25 is the aluminum alloy rolled article of examples 1-24,
wherein the
aluminum alloy rolled article has a width or length of from 6.5 mm to 40 m.
101071 Example 26 is the aluminum alloy rolled article of examples 1-25,
wherein the
aluminum alloy rolled article comprises or is composed of a 5voi aluminum
alloy.
[0108] Example 27 is the aluminum alloy rolled article of examples 1-26,
wherein the
aluminum alloy rolled article comprises or is composed of a 6xxx aluminum
alloy.
101091 Example 28 is the aluminum alloy rolled article of examples 1-27,
wherein the
aluminum alloy rolled article is formed by a process that does not comprise
cold rolling.
[0110] Example 29 is the aluminum alloy rolled article of examples 1-28,
wherein the
aluminum alloy rolled article is formed by a process that comprises: providing
a molten
aluminum alloy composition; continuously casting the molten aluminum alloy
composition to
form an aluminum alloy cast product; homogenizing the aluminum alloy cast
product to fonn
a homogenized aluminum alloy cast product; and rolling the homogenized
aluminum alloy
cast product to form the aluminum alloy rolled article having a thickness of
between 0.01 mm
and 7 mm, wherein the rolling is carried out at a temperature of between 300
C and 550 C.
[0111] Example 30 is a method for making an aluminum alloy rolled article,
comprising:
providing a molten aluminum alloy composition; continuously casting the molten
aluminum
alloy composition to form an aluminum alloy cast product; homogenizing the
aluininum alloy
cast product to form a homogenized aluminum alloy cast product; and rolling
the
homogenized aluminum alloy cast product to form an aluminum alloy rolled
article having a
thickness of between 0.01 inm and 7 mm, wherein the rolling is carried out at
a temperature
of between 300 C and 550 C.
[0112] Example 31 is the method of example 30, wherein homogenizing the
aluminum
alloy cast product includes controlling a homogenization temperature of the
aluminum alloy
cast product after exiting from a continuous caster, wherein the
homogenization temperature
is between 400 C and 600 C.
101131 Example 32 is the method of examples 30-31, wherein the aluminum alloy
cast
product is not cooled to below 400 C before the homogenizing.
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101141 Example 33 is the method of example 30-32, wherein rolling the
homogenized
aluminum alloy cast product includes controlling a rolling temperature during
rolling,
wherein a starting temperature of the rolling is between 400 C and 550 C,
and wherein an
exit temperature of the rolling is between 300 C and 500 C.
101151 Example 34 is the method of examples 30-33, wherein rolling the
homogenized
aluminum alloy cast product includes maintaining the temperature at or above a
recrystallization temperature of the homogenized aluminum alloy cast product.
101161 Example 35 is the method of examples 30-34, further comprising,
following the
rolling, subjecting the aluminum alloy rolled article to quenching.
[0117] Example 36 is the method of examples 30-35, wherein the method does not
comprise direct chill casting.
101181 Example 37 is the method of examples 30-36, wherein the method does not
comprise cold rolling the aluminum alloy rolled article to a final thickness.
[0119] Example 38 is the method of examples 30-37, wherein the aluminum alloy
rolled
article comprises at least a first surface portion, and wherein the first
surface portion is
substantially free of recrystallization texture or wherein the first surface
portion has volume
fractions of a cube texture component, a goss texture component, a brass
texture component,
an S texture component, and a copper texture component that are between 0% and
1%.
[0120] Example 39 is an aluminum alloy rolled article, which is formed by a
process
comprising: providing a molten aluminum alloy composition; continuously
casting the
molten aluminum alloy composition to form an aluminum alloy cast product;
homogenizing
the aluminum alloy cast product to form a homogenized aluminum alloy cast
product; and
rolling the homogenized aluminum alloy cast product to form the aluminum alloy
rolled
article having a thickness of between 0.01 mm and 7 mm, wherein the rolling is
carried out at
a temperature of between 300 C and 550 C.
[0121] Example 40 is the aluminum alloy rolled article of example 39, wherein
homogenizing the aluminum alloy cast product includes controlling a
homogenization
temperature of the aluminum alloy cast product after exiting from a continuous
caster,
wherein the homogenization temperature is between 400 C and 600 C.
101221 Example 41 is the aluminum alloy rolled article of examples 39-40,
wherein the
aluminum alloy cast product is not cooled to below 400 C before the
homogenizing.
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101231 Example 42 is the aluminum alloy rolled article of examples 39-41,
wherein rolling
the homogenized aluminum alloy cast product includes controlling a rolling
temperature
during rolling, wherein a starting temperature of the rolling is between 400
C and 550 C,
and wherein an exit temperature of the rolling is between 300 C and 500 C.
[0124] Example 43 is the aluminum alloy rolled article of examples 39-42,
wherein rolling
the homogenized aluminum alloy cast product includes maintaining the
temperature at or
above a recrystallization temperature of the homogenized aluminum alloy cast
product.
101251 Example 44 is the aluminum alloy rolled article of examples 39-43,
wherein the
process further comprises, following the rolling, subjecting the aluminum
alloy rolled article
to quenching.
101261 Example 45 is the aluminum alloy rolled article of examples 39-44,
wherein the
process does not comprise direct chill casting.
[0127] Example 46 is the aluminum alloy rolled article of examples 39-45,
wherein the
process does not comprise cold rolling the aluminum alloy rolled article to a
final thickness.
[0128] Example 47 is the aluminum alloy rolled article of examples 39-46,
comprising at
least a first surface portion, and wherein the first surface portion is
substantially free of
recrystallization texture or wherein the first surface portion has volume
fractions of a cube
texture component, a goss texture component, a brass texture component, an S
texture
component, and a copper texture component that are between 0% and 1%.
101291 Example 48 is the aluminum alloy rolled article of example 47, wherein
the first
surface portion has an isotropic texture.
[0130] Example 49 is the aluminum alloy rolled article of example 48, wherein
the
isotropic texture comprises a plurality of texture components, and wherein
each texture
component comprises less than 1 volume percent of the first surface portion.
[0131] Example 50 is the aluminum alloy rolled article of examples 47-49,
wherein the first
surface portion exhibits substantially uniform thinning during forming across
the first surface
portion in any direction relative to a rolling direction.
101321 Example 51 is an aluminum alloy article of manufacture, comprising an
aluminum
alloy rolled article of examples 1-29, an aluminum alloy rolled article of any
one of examples
39-50, or an aluminum alloy rolled article formed by the method of any one of
examples 30-
38.
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101331 Example 52 is the aluminum alloy article of manufacture of example 51,
wherein
the aluminum alloy rolled article is subjected to a stamping, forming, or
drawing process.
[0134] Example 53 is the aluminum alloy article of manufacture of examples 51-
52,
wherein the aluminum alloy article of manufacture is an automotive body part.
[0135] Example 54 is the aluminum alloy article of manufacture of example 53,
wherein
the automotive body part comprises a structural part.
[0136] Example 55 is the aluminum alloy article of manufacture of example 53,
wherein
the automotive body part is an outer panel.
[0137] Example 56 is the aluminum alloy article of manufacture of examples 51-
52,
wherein the aluminum alloy article of manufacture is an electronics device
housing.
[0138] Example 57 is the aluminum alloy article of manufacture of examples 51-
52,
wherein the aluminum alloy article of manufacture is an aerospace body part.
[0139] Example 58 is the aluminum alloy article of manufacture of examples 51-
52,
wherein the aluminum alloy article of manufacture is a transportation body
part.
[0140] Example 59 is the aluminum alloy article of manufacture of examples 51-
52,
wherein the aluminum alloy article of manufacture is a container part.
[0141] Example 60 is the aluminum alloy article of manufacture of example 59,
wherein
the aluminum alloy article of manufacture is a storage tank.
[0142] Example 61 is the aluminum alloy article of manufacture of example 59,
wherein
the aluminum alloy article of manufacture is an aluminum can end.
[0143]
The foregoing description of the embodiments, including
illustrated embodiments, has been presented only for the purpose of
illustration and
description and is not intended to be exhaustive or limiting to the precise
forms disclosed.
Numerous modifications, adaptations, and uses thereof will be apparent to
those skilled in the
art.
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