Note: Descriptions are shown in the official language in which they were submitted.
WO 2019/040356 PCT/US2018/047058
ALUMINUM ALLOY PRODUCTS HAVING SELECTIVELY
RECRYSTALLIZED MICROSTRUCTURE AND METHODS OF
MAKING
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Application
No. 62/548,013, filed on August 21, 2017.
FIELD
[0002] The present disclosure generally provides aluminum alloy products
having a
selectively recrystallized microstructure at the surface of the product. The
disclosure also
provides articles of manufacture made from aluminum alloy products, and
methods of
making aluminum alloy products, such as through casting and rolling. The
disclosure also
provides various end uses of such products, such as in automotive,
transportation, electronics,
and industrial applications.
BACKGROUND
[0003] Aluminum alloy products are desirable for use in a number of
different
applications, especially those where light weight, strength, and durability
are desirable. For
example, aluminum alloys are increasingly replacing steel as a structural
component of
automobiles and other transportation equipment. Because aluminum alloys are
generally
about 2.8 times less dense than steel, the use of such materials reduces the
weight of the
equipment and allows for substantial improvements in energy efficiency. Even
so, the use of
aluminum alloy products can pose certain challenges.
[0004] One particular challenge relates to the tendency of aluminum alloy
products to
undergo recrystallizati on during and following certain processing steps. In
metallurgy,
recrystallization refers to the process by which deformed grains (e.g., formed
as the result of
rolling or other mechanical shaping activities) reorient and convert into
defect-free grains that
nucleate and gradually replace the deformed grains. Recrystallization
generally improves the
ductility of the material, but generally does so at the expense of strength
and hardness. Thus,
in applications where strength and hardness are important, such as in certain
applications
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where aluminum alloys may be used to replace steel, recrystallization can
limit the use of
certain aluminum alloys as steel replacements.
SUMMARY
[0005] The covered embodiments of this disclosure are defined by the
claims, not this
summary. This summary provides a high-level overview of various aspects of the
invention
and introduces some of the concepts that are further described in the Detailed
Description
section below. This summary is not intended to identify key or essential
features of the
claimed subject matter, nor is it intended to be used in isolation to
determine the scope of the
claimed subject matter. The subject matter should be understood by reference
to appropriate
portions of the entire specification, any or all drawings, and each claim.
[0006] The present disclosure provides novel aluminum alloy articles that
have surface
portions with a higher degree of recrystallization or recrystallization
quotient than portions in
the interior of the article, where a higher portion of the aluminum alloy
material has a
recovered and/or unrecrystallized microstructure. Even though the aluminum
alloy articles of
the present disclosure are made from a monolithic aluminum alloy material,
they possess
certain benefits of cladded aluminum alloy materials, such as strength in the
core of the
article and ductility in the clad of the article. The present disclosure also
provides methods of
making such aluminum alloy articles and articles of manufacture formed from
such
aluminum alloy articles. In some examples, the aluminum alloy article is a
rolled article,
such as an aluminum alloy sheet, where the material near the surface of the
sheet has a
recrystallized microstructure and the material in the interior of the sheet
has a recovered
and/or unrecrystallized microstructure. The resulting article exhibits the
strength benefits of
material in a recovered and/or unrecrystallized microstructure coupled with
desirable
bendability and corrosion properties of material in a recrystallized
microstructure.
[0007] The present disclosure provides an aluminum alloy article, which is
comprised of
an aluminum alloy material and further comprises. (a) a first surface portion;
(b) a second
surface portion opposing the first surface portion; and (c) an intermediate
portion between the
first surface portion and the second surface portion; wherein the first
surface portion and the
second surface portion comprise a rolled surface; and wherein the aluminum
alloy material of
the first surface portion and the second surface portion have a higher degree
of
recrystallization or recrystallization quotient than the aluminum alloy
material of the
intermediate portion. In some embodiments, the aluminum alloy article is an
ingot, a strip, a
shate, a slab, a billet, or other aluminum alloy product. In some other
embodiments, the
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aluminum alloy article is a rolled aluminum alloy article, which is formed by
a process that
includes rolling the aluminum alloy article, for example, until a desired
thickness is achieved.
In some embodiments, the rolled aluminum alloy article is an aluminum alloy
sheet, shate,
plate, extrusion, casting or forging in any suitable temper, e.g., an 0 temper
or a temper
ranging from the Ti to T9 tempers, and any suitable gauge. In some
embodiments, the
aluminum alloy article is made from a 7xxx series alloy as provided herein.
[0008] The present disclosure also provides a method of making an aluminum
alloy
article, the method comprising: providing an aluminum alloy, wherein the
aluminum alloy is
provided in a molten state as a molten aluminum alloy; casting the molten
aluminum alloy to
form an aluminum alloy cast product; homogenizing the aluminum alloy cast
product to form
a homogenized aluminum alloy cast product; rolling the homogenized aluminum
alloy cast
product to form a first rolled aluminum alloy product having a first
thickness, wherein the
rolling comprises one or more hot rolling passes and one or more cold rolling
passes, wherein
the one or more hot rolling passes precede the one or more cold rolling
passes; annealing the
first rolled aluminum alloy product at a temperature of not more than 50 C
above the
minimum recrystallization temperature of the aluminum alloy to form a first
annealed
aluminum product; and rolling the first annealed aluminum alloy product to
form a second
rolled aluminum product having a second thickness. In some embodiments
thereof, the
aluminum alloy articles are subjected to a final solution heat treatment, for
example, the
article can be solution heat treated either through a CASH (continuous
annealing and solution
heat treatment) or hot stamping process.
[0009] The disclosure also provides an aluminum alloy article made by the
processes
disclosed herein.
[0010] Also disclosed are articles of manufacture comprising the disclosed
aluminum
alloy articles. In some embodiments, the article of manufacture comprises a
rolled aluminum
alloy article. Examples of such articles of manufacture include, but are not
limited to, a
component of an automobile, truck, trailer, train, railroad car, airplane,
such as a body panel
or other part for any of the foregoing, a bridge, a pipeline, a pipe, a
tubing, a boat, a ship, a
storage container, a storage tank, an article of furniture, a window, a door,
a railing, a
functional or decorative architectural piece, a pipe railing, an electrical
component, a conduit,
a beverage container, a food container, or a foil. In some embodiments, the
articles of
manufacture are automotive or transportation body parts, including motor
vehicle body parts
(e.g., bumpers, side beams, roof beams, cross beams, pillar reinforcements,
inner panels,
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outer panels, side panels, hood inners, hood outers, and trunk lid panels).
The articles of
manufacture can also include aerospace products and electronic device
housings.
[0011] Additional aspects and embodiments are set forth in the detailed
description,
claims, non-limiting examples, and drawings, which are included herein.
BRIEF DESCRIPTION OF THE FIGURES
[0012] 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.
[0013] FIG. 1 provides a schematic overview of a process for preparing
aluminum alloy
articles.
[0014] FIG. 2 shows an optical micrograph (OM) of Alloy Al, which is lab
rolled and
processed, and which shows a recovered and/or unrecrystallized microstructure
through the
thickness of the sample.
[0015] FIG. 3A shows an optical micrograph (OM) of Alloy Al, which is plant
rolled
with inter-annealing. FIG. 3B shows a surface portion from FIG. 3A, showing a
recrystallized microstructure. FIG. 3C shows nine black and white reduced-size
versions of
FIG. 3B, highlighting various colors shown in FIG. 3B, which may reveal
certain features.
FIG. 3D shows a center portion from FIG. 3A, showing a recovered and/or
unrecrystallized
microstructure. FIG. 3E shows nine black and white reduced-size versions of
FIG. 3D,
highlighting various colors shown in FIG. 3D, which may reveal certain
features. For
example, significant horizontal lines are shown in the images of FIG. 3E,
corresponding to
the recovered and/or unrecrystallized microstructure with various crystal
orientation. For the
surface portion shown in FIGs. 3B and 3C, little of the horizontal structure
is seen, indicated
significantly more recrystallized microstructure at the surface portion.
[0016] FIG 4A shows an optical micrograph of Alloy AS, plant rolled without
inter-
annealing during the cold rolling process. FIG. 4B shows a surface portion
from FIG. 4A,
showing recrystallized microstructure. FIG. 4C is from the center portion from
FIG. 4A,
showing recovered and/or unrecrystallized microstructure.
[0017] Cross-sections of aluminum alloy sheet recorded by EBSD are depicted
in the
images shown on the right hand side of FIG. 5A, FIG. 5B, and FIG. 5C, where
the aluminum
alloy sheet of Alloy Al is rolled to a final gauge and finished with a T6
temper. The low
angle boundaries (2-15 ) are marked as darker-color horizontal lines (shown
separately in
black in the top left images of FIGs. 5A-5C), while the medium to high angle
boundaries
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(>15 ) are marked as lighter-color horizontal lines (also shown separately in
black the bottom
left images of FIGs. 5A-5C). FIG. 5A is Alloy Al lab processed, without inter-
annealing
during the cold rolling process, which has a uniform microstructure that is
recovered and/or
unrecrystallized throughout the whole thickness, while FIG. 5B is Alloy Al
plant processed,
with inter-annealing during the cold rolling process, which shows a
recrystallization
microstructure near the surface and a recovered and/or unrecrystallized
microstructure in the
center. FIG. 5C shows Alloy AS, plant processed, without inter-annealing
during the cold
rolling process, which has a microstructure between that shown in FIG. 5A and
FIG. 5B.
[0018] FIG. 6 shows the results of bendability testing for certain aluminum
alloy articles,
where bendability is tested in the longitudinal and transverse direction
(relative to the rolling
direction).
[0019] FIG. 7A, FIG. 7B, FIG. 7C, FIG. 7D, and FIG. 7E show photographs of
aluminum
alloy sheet following testing for exfoliation corrosion.
[0020] FIG. 8 shows the results of yield strength testing for a series of
aluminum alloy
sheets.
DETAILED DESCRIPTION
[0021] The present disclosure provides aluminum alloy articles that exhibit
a novel
combination of recrystallized, and recovered and/or unrecrystallized,
microstructure, and
methods of making such articles. These articles can exhibit increased strength
over articles
made from fully recrystallized material, while retaining the bendability and
corrosion
resistance that such materials generally possess.
Definitions and Descriptions:
[0022] As used herein, the terms "invention," "the invention," "this
invention" and "the
present invention" are intended to refer broadly to all of the subject matter
of this patent
application and the claims below. Statements containing these terms should be
understood
not to limit the subject matter described herein or to limit the meaning or
scope of the patent
claims below.
[0023] In this description, reference is made to alloys identified by AA
numbers and
other related designations, such as "series" or "7xxx." For an understanding
of the number
designation system most commonly used in naming and identifying aluminum and
its alloys,
see "International Alloy Designations and Chemical Composition Limits for
Wrought
Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum
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Association Alloy Designations and Chemical Compositions Limits for Aluminum
Alloys in
the Form of Castings and Ingot," both published by The Aluminum Association.
[0024] As used herein, a plate generally has a thickness of greater than
about 15 mm. For
example, a plate may refer to an aluminum product having a thickness of
greater than about
15 mm, greater than about 20 mm, greater than about 25 mm, greater than about
30 mm,
greater than about 35 mm, greater than about 40 mm, greater than about 45 mm,
greater than
about 50 mm, or greater than about 100 mm.
[0025] As used herein, a shate (also referred to as a sheet plate)
generally has a thickness
of from about 4 mm to about 15 mm For example, a shate may have a thickness of
about 4
mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm,
about
11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
[0026] As used herein, a sheet generally refers to an aluminum product
having a
thickness of less than about 4 mm. For example, a sheet may have a thickness
of less than
about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm,
less than
about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).
[0027] As used herein, the term slab indicates an alloy thickness in a
range of 5 mm to 50
mm. For example, a slab may have a thickness of about 5 mm, 10 mm, 15 mm, 20
mm, 25
mm, 30 mm, 35 mm, 40 mm, 45 mm, or 50 mm.
[0028] Reference may be made in this application to alloy temper or
condition For an
understanding of the alloy temper descriptions most commonly used, see
"American National
Standards (ANSI) H35 on Alloy and Temper Designation Systems." An F condition
or
temper refers to an aluminum alloy as fabricated. An 0 condition or temper
refers to an
aluminum alloy after annealing. An Hxx condition or temper, also referred to
herein as an H
temper, refers to 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
aluminum alloy cooled
from hot working and artificially aged (at elevated temperatures). A T6
condition or temper
refers to an aluminum alloy solution heat treated and artificially aged. A T7
condition or
temper refers to an aluminum alloy solution heat treated and artificially
overaged. A T8x
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condition or temper refers to an aluminum alloy solution heat treated, cold
worked, and
artificially aged. A T9 condition or temper refers to an aluminum alloy
solution heat treated,
artificially aged, and cold worked. A W condition or temper refers to an
aluminum alloy
after solution heat treatment.
[0029] As used herein, terms such as "cast metal product," "cast product,"
"cast
aluminum alloy product," and the like are interchangeable and refer to a
product produced by
direct chill casting (including direct chill co-casting) or semi-continuous
casting, continuous
casting (including, for example, by use of a twin belt caster, a twin roll
caster, a block caster,
or any other continuous caster), electromagnetic casting, hot top casting, or
any other casting
method.
[0030] As used herein, the meaning of "room temperature" can include a
temperature of
from about 15 C to about 30 C, for example about 15 C, about 16 C, about
17 C, about
18 C, about 19 C, about 20 C, about 21 C, about 22 C, about 23 C, about
24 C, about
25 C, about 26 C, about 27 C, about 28 C, about 29 C, or about 30 C. As
used herein,
the meaning of "ambient conditions" can include temperatures of about room
temperature,
relative humidity of from about 20 % to about 100 %, and barometric pressure
of from about
975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be
about 20 %,
about 21 %, about 22 %, about 23 %, about 24 %, about 25 %, about 26 %, about
27 %, about
28 %, about 29 %, about 30 %, about 31 %, about 32 %, about 33 %, about 34
(i/o, about 35
Ii/o, about 36 %, about 37 %, about 38 %, about 39 %, about 40 %, about 41 %,
about 42 %,
about 43 %, about 44 %, about 45 %, about 46 %, about 47 %, about 48 %, about
49 %, about
50 %, about 51 %, about 52 %, about 53 %, about 54 %, about 55 %, about 56 %,
about 57
%, about 58 %, about 59 %, about 60 %, about 61 %, about 62 %, about 63 %,
about 64 %,
about 65 %, about 66 %, about 67 %, about 68 %, about 69 %, about 70 %, about
71 %, about
72 %, about 73 %, about 74 %, about 75 %, about 76 %, about 77 %, about 78 %,
about 79
%, about 80 %, about 81 %, about 82%, about 83 %, about 84 %, about 85 %,
about 86 %,
about 87 %, about 88 0/3, about 89 %, about 90 %, about 91 %, about 92 %,
about 93 %, about
94 %, about 95 %, about 96 %, about 97 %, about 98 %, about 99 %, about 100 %,
or
anywhere in between. For example, barometric pressure can be about 975 mbar,
about 980
mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about
1005 mbar,
about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030
mbar,
about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or
anywhere in
between.
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[0031] All ranges disclosed herein are to be understood to encompass any
and all
subranges subsumed therein. For example, a stated range of "1 to 10" should be
considered
to include any and all subranges between (and inclusive of) the minimum value
of 1 and the
maximum value of 10; that is, all subranges beginning with a minimum value of
1 or more,
e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.
Unless stated
otherwise, the expression "up to" when referring to the compositional amount
of an element
means that element is optional and includes a zero percent composition of that
particular
element. Unless stated otherwise, all compositional percentages are in weight
percent (wt.
%).
[0032] As used herein, the meaning of "a," "an," and "the" includes
singular and plural
references unless the context clearly dictates otherwise.
[0033] In the following examples, the aluminum alloy products and their
components are
described in terms of their elemental composition in weight percent (wt. %).
In each alloy,
the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of all
impurities.
[0034] Incidental elements, such as grain refiners and deoxidizers, or
other additives may
be present in the invention and may add other characteristics on their own
without departing
from or significantly altering the alloy described herein or the
characteristics of the alloy
described herein.
[0035] Unavoidable impurities, including materials or elements may be
present in the
alloy in minor amounts due to inherent properties of aluminum or leaching from
contact with
processing equipment. Some impurities typically found in aluminum include iron
and
silicon. The alloy, as described, may contain no more than about 0.25 wt. % of
any element
besides the alloying elements, incidental elements, and unavoidable
impurities.
Aluminum Alloy Article
[0036] In at least one aspect, the present disclosure provides an aluminum
alloy article,
comprising an aluminum alloy material and having a first surface portion; a
second surface
portion opposing the first surface portion; and an intermediate portion
between the first
surface portion and the second surface portion; wherein the aluminum alloy
material of the
first surface portion and the second surface portion have a higher degree of
recrystallization
or recrystallization quotient than the aluminum alloy material of the
intermediate portion. In
some embodiments thereof, the first surface portion and the second surface
portion each
comprise a rolled surface.
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[0037] The aluminum alloy article can comprise any suitable aluminum alloy
material
ranging from lxxx series aluminum alloys to 8xxx series aluminum alloys. In
some
embodiments, the aluminum alloy material is a 5xxx series aluminum alloy, a
6xxx series
aluminum alloy, or a 7xxx series aluminum alloy. In some embodiments, the
aluminum alloy
material is a 7xxx series aluminum alloy that comprises, among other standard
elements, an
amount of zirconium (Zr), for example, from 0.01 wt. % to 0.50 wt. %, based on
the total
elemental composition of the alloy.
[0038] In some embodiments where the aluminum alloy material is a 7xxx
series
aluminum alloy, the aluminum alloy material can be selected from any suitable
7xxx series
aluminum alloy, including, but not limited to, the following 7xxx series
aluminum alloys:
AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108,
AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030,
AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005,
AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023,
AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136,
AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149,7204, AA7249,
AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255,
AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076,
AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095,
and AA7099.
[0039] In some embodiments, the aluminum alloy material has the elemental
composition
set forth in Table 1.
Table 1
Element Weight Percentage (wt. %)
Zn 4.0 - 15.0
Cu 0.1 - 3.5
Mg 1.0 - 4.0
Fe 0.05 - 0.50
Si 0.05 - 0.30
Zr 0.01 - 0.50
Mn 0 - 0.25
Cr 0 - 0.20
Ti 0 - 0.15
Impurities 0 - 0.15
Al Remainder
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[0040] In some embodiments, the aluminum alloy material has the elemental
composition
set forth in Table 2.
Table 2
Element Weight Percentage (wt. %)
Zn 5.6 - 9.3
Cu 0.2 - 2.6
Mg 1.4 - 2.8
Fe 0.10 - 0.35
Si 0.05 - 0.20
Zr 0.05 - 0.25
Mn 0 - 0.05
Cr 0 - 0.10
Ti 0 - 0.05
Impurities 0 - 0.15
Al Remainder
[0041] Optionally, the aluminum alloy material includes zinc (Zn) in an
amount of from
4% to 15% (e.g., from 5.4% to 9.5%, from 5.6% to 9.3%, from 5.8% to 9.2%, or
from 4.0%
to 5.0%) based on the total weight of the alloy. For example, the aluminum
alloy material
can include 4.0%, 4.1%, 4.2%, 4.3%, 4.4 %, 4.5%, 4.6 %, 4.7%, 4.8 %, 4.9 %,
5.0%, 5.1%,
5.2 /0, 5.3%, 5.40/, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%,
6.4%, 6.5%,
6.6%, 6.7%, 6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%,
7.9%,
8.0%, 8.1%, 8.2%, 8.3%, 8.4%, 8.5%, 8.6%, 8.7%, 8.8%, 8.9%, 9.0%, 9.1%, 9.2%,
9.3%,
9.4%, 9.5%, 9.6% 9.7%, 9.8%, 9.9%, 10.0%, 10.1%, 10.2%, 10.3%, 10.4%, 10.5%,
10.6%,
10.7%, 10.8%, 10.9%, 11.0%, 11.1%, 11.2%, 11.3%, 11.4%, 11.5%, 11.6%, 11.7%,
11.8%,
11.9%, 12.0%, 12.1%, 12.2%, 12.3%, 12.4%, 12.5%, 12.6%, 12.7%, 12.8?/O, 12.9%,
13.0%,
13.1%, 13.2%, 13.3%, 13.4%, 13.5%, 13.6%, 13.7%, 13.8%, 13.9%, 14.0%, 14.1%,
14.2%,
14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%, 14.9%, or 15.0% Zn. All are
expressed in wt.
[0042] Optionally, the aluminum alloy material includes copper (Cu) in an
amount of
from 0.1% to 3.5% (e.g., from 0.2% to 2.6%, from 0.3% to 2.5%, or from 0.15%
to 0.6%)
based on the total weight of the alloy. For example, the aluminum alloy
material can include
0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%,
0.21%,
0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.35%, 0.40%,
0.45%,
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0.50%, 0.55%, 0.60%, 0.65%, 0.70% 0.75%, 0.80%, 0.85%, 0.90%, 0.95%, 1.00o,
1.100,
1.200, 1.3%, 1.4%, 1.50o, 1.600, 1.700, 1.800, 1.9%, 2.00o, 2.10o, 2.20A,
2.30o, 2.40o, 2.50o,
2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.10A, 3.2%, 3.30, 3.40o, or 3.5% Cu. All are
expressed in
wt. A.
[0043] Optionally, the aluminum alloy material includes magnesium (Mg) in
an amount
of from 1.0% to 4.0% (e.g., from 1.0% to 3.0%, from 1.4% to 2.8%, or from 1.6%
to 2.6%).
For example, the aluminum alloy material can include 1.00o, 1.1%, 1.2%, 1.3%,
1.4%, 1.5%,
1.6%, 1.7%, 1.8%, 1.9 /o, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8
A, 2.9%,
3.00o, 3.1%, 3.2%, 3.30o, 3.40, 3.50, 3.6%, 3.70, 3.8%, 3.9%, or 4.0% Mg. All
are
expressed in wt. %.
[0044] Optionally, the aluminum alloy material includes a combined content
of Zn, Cu,
and Mg ranging from 50o to 14% (e.g., from 5.5% to 13.5%, from 6% to 13%, from
6.5% to
12.5%, or from 7 A to 12%). For example, the combined content of Zn, Cu, and
Mg can be
5.00o, 5.500, 6.00o, 6.500, 7.000, 7.50o, 8.00o, 8.500, 9.00o, 9.5%, 10.000,
10.500, 11.000,
11.50o, 12.00o, 12.5%, 13.00o, 13.5%, or 14.00o. All are expressed in wt. %.
[0045] Optionally, the aluminum alloy material includes iron (Fe) in an
amount of from
0.05% to 0.50% (e.g., from 0.10% to 0.35 4) or from 0.10% to 0.25%) based on
the total
weight of the alloy. For example, the aluminum alloy material can include
0.0507O, 0.06%,
0.07%, 0.08%, 0.09%, 0.10% 0.11 ./O, 0.12 /O, 0.13%, 0.14%, 0.150o, 0.16 A,
0.17%, 0.18 A,
0.19 A, 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% Fe. All are expressed
in wt.
00.
[0046] Optionally, the aluminum alloy material includes silicon (Si) in an
amount of from
0.05 A to 0.30 /o (e.g., from 0.050o to 0.25 0 or from 0.07% to 0.150o) based
on the total
weight of the alloy. For example, the aluminum alloy material can include
0.050o, 0.06%,
0.0700, 0.0800, 0.0900, 0.1000 0.1100, 0.12 A, 0.13 /O, 0.14%, 0.1500, 0.16
/O, 0.17%, 0.18%,
0.19%, 0.20%, 0.21%, 0.22 A, 0.23%, 0.24 A, 0.25 A, 0.26 %, 0.27 %, 0.28%,
0.29%, or
0.30% Si. All are expressed in wt. %.
[0047] Optionally, the aluminum alloy material includes zirconium (Zr) in
an amount of
from 0.0100 to 0.5000 (e.g., from 0.0500 to 0.25 /O, or from 0.050o to 0.20%
or from 0.09 A to
0.150/o) based on the total weight of the alloy. For example, the aluminum
alloy material can
include 0.01%, 0.02 A, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%,
0.11%,
0.12%, 0.13%, 0.14%, 0.15%, 0.16 A, 0.17%, 0.18 A, 0.19%, 0.20%, 0.21%, 0.22%,
0.23%,
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0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30 /O, 0.310o, 0.32%, 0.33%, 0.34
/O, 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%,
0.480 , 0.49%, 0.50 /o Zr. In other examples, the alloys can include Zr in an
amount less than
0.05% (e.g., 0.04%, 0.03%, 0.02 /0, or 0.01%) based on the total weight of the
alloy. All are
expressed in wt. 0/0.
[0048] In some instances, the presence of Zr in the alloy may form Al3Zr
dispersoids,
which can assist in pinning the grain boundaries of the aluminum alloy
material. In the
region of the aluminum alloy article near a rolled surface, the higher strain
introduced from
the rolling process can at least partially overcome the pinning and allow for
a higher degree
of recrystallization or recrystallization quotient. Meanwhile, in the interior
portions of the
aluminum alloy article, the pinning is not overcome and recrystallization
occurs to a much
lower degree. In some embodiments, Al3Zr dispersoids are present in the
aluminum alloy
material, the dispersoids having a number-average diameter ranging from 1 nm
to 20 nm.
[0049] Optionally, the aluminum alloy material includes manganese (Mn) in
an amount
of up to 0.25ci0 (e.g., from 0.010o to 0.100o or from 0.02')//0 to 0.05c,/o)
based on the total
weight of the alloy. For example, the aluminum alloy material can include
0.010o, 0.02%,
0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.100o, 0.1100, 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%, or 0.25%
Mn.
In some cases, Mn is not present in the alloy (i.e., 0 4)). All are expressed
in wt. %.
[0050] Optionally, the aluminum alloy material includes chromium (Cr) in an
amount of
up to 0.20%, or up to 0.1000 (e.g., from 0.010o to 0.1000, from 0.01% to 0.05
/o, or from
0.03% to 0.05%) based on the total weight of the alloy. For example, the
aluminum alloy
material can include 0.01%, 0.02%, 0.03%, 0.04%, 0.050o, 0.06%, 0.07%, 0.08%,
0.09%,
0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20%
Cr. In
some cases, Cr is not present in the alloy (i.e., 0%). All are expressed in
wt. %.
[0051] Optionally, the aluminum alloy material includes titanium (Ti) in an
amount of up
to 0.150o (e.g., from 0.00100 to 0.100o, from 0.0010o to 0.050o, or from
0.003ciO to 0.0351)/O)
based on the total weight of the alloy. For example, the alloy can include
0.001%, 0.002%,
0.003 4), 0.004%, 0.0050o, 0.006%, 0.007%, 0.008%, 0.009%, 0.01000, 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, 0.039%, 0.040%, 0.041%,
0.042%,
0.043%, 0.044%, 0.045%, 0.046%, 0.047%, 0.048 A), 0.049%, 0.050% , 0.055%,
0.060%,
0.065%, 0.070%, 0.075%, 0.080%, 0.085%, 0.090%, 0.095%, 0.100%, 0.110%, 0.120
A),
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0.130%, 0.140%, or 0.150% Ti. In some cases, Ti is not present in the alloy
(i.e., 0%). All
are expressed in wt. %.
[0052] Optionally, the aluminum alloy material includes one or more
elements selected
from the group consisting of Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho,
Er, Tm, Yb,
and Lu in an amount of up to 0.10% (e.g., from 0.01% to 0.10%, from 0.01% to
0.05%, or
from 0.03% to 0.05%), based on the total weight of the alloy. For example, the
aluminum
alloy material can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%,
0.08%,
0.09%, or 0.10 % of one or more elements selected from the group consisting of
Y, La, Ce,
Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu. All are expressed in
wt. %
[0053] Optionally, the aluminum alloy material includes one or more
elements selected
from the group consisting of Mo, Nb, Be, B, Co, Sn, Sr, V, In, Hf, Ag, Sc, and
Ni in an
amount of up to 0.10% (e.g., from 0.01% to 0.10%, from 0.01% to 0.05%, or from
0.03% to
0.05%), based on the total weight of the alloy. For example, the aluminum
alloy material can
include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.10
% of
one or more elements selected from the group consisting of Mo, Nb, Be, B, Co,
Sn, Sr, V, In,
Hf, Ag, Sc, and Ni. All are expressed in wt. %.
[0054] Optionally, the aluminum alloy material includes other minor
elements,
sometimes referred to as impurities, in amounts of 0.15% or below, 0.14% or
below, 0.13%
or below, 0.12% or below, 0.11% or below, 0.10% or below, 0.09% 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. In some embodiments, these impurities
include, but are
not limited to, Ga, Ca, Bi, Na, Pb, or combinations thereof. Accordingly, in
some
embodiments, one or more elements selected from the group consisting of Ga,
Ca, Bi, Na,
and Pb may be present in the aluminum alloy material in amounts of 0.15% or
below, 0.14%
or below, 0.13% or below, 0.12% or below, 0.11% or below, 0.10% or below,
0.09% 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. The sum of all impurities
does not
exceed 0.15% (e.g., 0.10%). All are expressed in wt. %. The remaining
percentage of the
alloy is aluminum.
[0055] The alloy compositions disclosed herein, including the aluminum
alloy material of
any of foregoing embodiments, have aluminum (Al) as a major component, for
example, in
an amount of at least 85.0% of the alloy. Optionally, the alloy compositions
have at least
85.5% Al, or at least 86.0% Al, or at least 86.5% Al, or at least 87.0% Al, or
at least 87.5%
Al, or at least 88.0% Al, or at least 88.5% Al, or at least 89.0% Al, or at
least 89.5% Al, or at
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least 90.0% Al, or at least 90.5% Al, or at least 91.0% Al, or at least 91.5%
Al, or at least
92.0% Al. All are expressed in wt. %.
[0056] The aluminum alloy articles disclosed herein can be any suitable
aluminum alloy
article. As noted above, the articles have a first surface portion and an
opposing second
surface portion. In some cases, the surface of the first surface portion and
the surface of the
second surface portion represent opposite sides of an article, such that the
two surfaces may
be parallel or generally parallel to each other or disposed away from each
other and separated
by a thickness, e.g., a first thickness, which may represent a distance
between the two
surfaces along a line perpendicular to the two surfaces or the shortest
distance between the
two surfaces.
[0057] As noted above, in some embodiments, the first surface portion
comprises a rolled
surface and the second surface portion comprises a rolled surface, for
example, the surfaces
of an article formed by rolling a cast aluminum product, such as a slab, an
ingot, a shate, a
sheet, a plate and the like. In some embodiments, these rolled surfaces are
formed according
to the processes set forth below. For example, the rolled surface of the first
surface portion
and the rolled surface of the second surface portion may be formed by a
process that
comprises cold rolling. In some embodiments, the cold rolling is preceded by
hot rolling. In
some embodiments, the cold rolling is preceded by hot rolling.
[0058] The aluminum alloy article can have any suitable physical
configuration.
Optionally, the aluminum alloy article is a rolled aluminum alloy plate, shate
or sheet. In
some embodiments, the aluminum alloy article is a rolled aluminum alloy shate.
The rolled
aluminum alloy shate can have any suitable thickness, but, in some
embodiments, it has a
thickness ranging from 4 mm to 15 mm, or no more than 14 mm, or no more than
13 mm, or
no more than 12 mm, or no more than 11 mm, or no more than 10 mm, or no more
than 9
mm, or no more than 8 mm, or no more than 7 mm, or no more than 6 mm, or no
more than 5
mm. In some embodiments, the aluminum alloy article is a rolled aluminum alloy
sheet. The
rolled aluminum alloy sheet can have any suitable thickness, but, in some
embodiments, it
has a thickness ranging from 0.05 mm to 4 mm, or no more than 3 mm, or no more
than 2
mm, or no more than 1 mm, or no more than 0.5 mm, or no more than 0.3 mm, or
no more
than 0.1 mm. In some embodiments, the aluminum alloy article is a rolled
aluminum alloy
shate or a rolled aluminum alloy sheet having a thickness of 15 mm, or 14 mm,
or 13 mm, or
12 mm, or 11 mm, or 10 mm, or 9 mm, or 8 mm, or 7 mm, or 6 mm, or 5 mm, or 4
mm, or 3
mm, or 2 mm, or 1 mm, or 0.5 mm, or 0.3 mm, or 0.1 mm.
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[0059] The disclosure refers to certain "surface portion(s)," such as a
first surface portion
and a second surface portion. Such surface portions include a surface of the
article, such as a
rolled surface, and a certain amount of material (e.g., a uniform depth of
material) beneath
the surface and along the thickness of the article (i.e., the line running
perpendicular to the
respective surfaces of the first surface portion and the second surface
portion). Optionally,
the first surface portion extends from the surface of the first surface
portion to a depth of no
more than 40.0%, or no more than 35.0%, or no more than 33.3%, or no more than
30.0%, or
no more than 25.0%, or no more than 20.0%, or no more than 15.0%, or no more
than 10.0%,
of the thickness of the aluminum alloy article. In some embodiments, the
second surface
portion extends from the surface of the second surface portion to a depth of
no more than
40.0%, or no more than 35.0%, or no more than 33.3%, or no more than 30.0%, or
no more
than 25.0%, or no more than 20.0%, or no more than 15.0%, or no more than
10.0%, of the
thickness of the aluminum alloy article. In some embodiments, the first
surface portion and
the second surface portion are of the same depth, i.e., are symmetrical in
depth with respect to
the midpoint of the distance between the two surfaces. In some other
embodiments, however,
the first surface portion and the second surface portion have different
depths.
[0060] The disclosure also refers to an "intettnediate portion" that lies
between the first
surface portion and the second surface portion. Optionally, the intermediate
portion includes
the remaining material between the two surfaces that is not included in the
first surface
portion and the second surface portion, such that the intermediate portion
extends from the
depth of the first surface portion to the depth of the second surface portion.
Thus, in some
embodiments, all material between the two surfaces is included in either the
first surface
portion, the second surface portion, or the intermediate portion. Optionally,
the intermediate
portion does not include all of the remaining material between the two
surfaces that is not
included in the first surface portion and the second surface portion. In some
embodiments,
the intermediate portion lies between the depth of the first surface portion
and the depth of
the second surface portion, includes the midpoint in the thickness between the
depth of the
first surface portion and the depth of the second surface portion, and
includes no more than
10.0%, or no more than 20.0%, or no more than 30.0%, or no more than 40.0%, or
no more
than 50.0%, or no more than 60.0%, or no more than 70.0%, or no more than
80.0%, or no
more than 90.0%, or no more than 95.0%, or no more than 97.0%, or no more than
99.0%, of
the thickness between the depth of the first surface portion and the depth of
the second
surface portion. In some embodiments, the midpoint in the thickness between
the depth of
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the first surface portion and the depth of the second surface portion lies at
the midpoint in the
thickness of the intermediate portion.
[0061] The disclosure provides aluminum alloy articles in which the
aluminum alloy
material of the first surface portion has a higher degree of recrystallization
or recrystallization
quotient than the aluminum alloy material of the intermediate portion. In some
embodiments,
the second surface portion also has a higher degree of recrystallization or
recrystallization
quotient than the aluminum alloy material of the intermediate portion, such
that, in the case
of an aluminum alloy plate, shate or sheet, the areas nearer to the two
surfaces of the plate,
shate or sheet have a higher degree of recrystallization or recrystallization
quotient than the
area lying in the interior of the plate, shate or sheet.
[0062] The degree of recrystallization or recrystallization quotient can be
determined by
any suitable method known in the art. For example, in a micrograph, such as a
scanning
electron micrograph (SEM) or an optical micrograph (OM), the higher degree of
recrystallization recrystallization quotient can be observed in terms of a
grain structure
having a higher degree of uniformity. In some other examples, electron
backscatter
diffraction (EBSD) can also be used to assess the degree of recrystallization.
Optionally, the
degree of recrystallization is set forth in terms of a "recrystallization
quotient," which, as
used herein, refers to the formula: 1 ¨ LAGB/(MAGB+HAGB). In some embodiments,
a
recrystallization quotient may refer to or be representative of a percentage,
amount, or
volume of material that is recrystallized as compared to a total amount or
volume of material.
LAGB refers to the quantity of grain boundaries in a given volume having
misorientation
between adjacent grains of 2 to 15 (i.e., a quantity of low-angle grain
boundaries). MAGB
refers to the quantity of grain boundaries in a given volume having
misorientation between
adjacent grains of greater than 15 but no more than 30 (i.e., the quantity
of medium-angle
grain boundaries). HAGB refers to the quantity of grain boundaries in a given
volume having
misorientation between adjacent grains of more than 30 (i.e., the quantity of
high-angle
grain boundaries). Quantities or values of LAGB, MAGB, and HAGB may be
determined by
measuring the angle of misorientation between adjacent grains, as recorded by
EBSD. The
recovery or recrystallization of materials may reduce the stored energy in
materials when
heavily deformed materials are annealed at high temperature. Recovery competes
with
recrystallization, as both are driven by the stored energy during annealing.
Recovery can be
defined as annealing processes occurring in deformed materials that occur
without the
migration of a high-angle grain boundary. The defoimed structure is often a
cellular structure
with walls having dislocation angles. As recovery proceeds, these cell walls
undergo a
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transition towards a genuine subgrain structure. This occurs through a gradual
elimination of
extraneous dislocations and the rearrangement of the remaining dislocations
into low-angle
grain boundaries. However, recrystallization is the formation of a new grain
structure in a
deformed material by the formation and migration of high angle grain
boundaries driven by
the stored energy of deformation. Therefore, the LAGB is eliminated during the
recrystallization process.
[0063] Optionally, the aluminum alloy material of the first surface portion
has a
recrystallization quotient that is higher than the recrystallization quotient
of the aluminum
alloy material of the intermediate portion. Optionally, the first surface
portion has a
recrystallization quotient that at least 0.01 higher (e.g., 0.01-1.0), or at
least 0.03 higher, or at
least 0.05 higher, or at least 0.07 higher, or at least 0.10 higher, or at
least 0.15 higher, or at
least 0.20 higher, or at least 0.25 higher, or at least 0.30 higher, or at
least 0.35 higher, or at
least 0.40 higher, or at least 0.45 higher, or at least 0.50 higher, than the
recrystallization
quotient of the aluminum alloy material of the intermediate portion.
[0064] Optionally, the aluminum alloy material of the second surface
portion has a
recrystallization quotient that is higher than the recrystallization quotient
of the aluminum
alloy material of the intermediate portion. Optionally, the second surface
portion has a
recrystallization quotient that at least 0.01 higher (e.g., 0.01-1.0), or at
least 0.03 higher, or at
least 0.05 higher, or at least 0.07 higher, or at least 0.10 higher, or at
least 0.15 higher, or at
least 0.20 higher, or at least 0.25 higher, or at least 0.30 higher, or at
least 0.35 higher, or at
least 0.40 higher, or at least 0.45 higher, or at least 0.50 higher, than the
recrystallization
quotient of the aluminum alloy material of the intermediate portion.
[0065] Optionally, the aluminum alloy material of the first surface portion
has a
recrystallization quotient of at least 0.50, or at least 0.55, or at least
0.60, or at least 0.65, or at
least 0.70, or at least 0.75, or at least 0.80, or at least 0.85, or at least
0.90. For example, the
first surface portion may have a recrystallization quotient of 0.5 to 1Ø
[0066] Optionally, the aluminum alloy material of the second surface
portion has a
recrystallization quotient of at least 0.50, or at least 0.55, or at least
0.60, or at least 0.65, or at
least 0.70, or at least 0.75, or at least 0.80, or at least 0.85, or at least
0.90. For example, the
second surface portion may have a recrystallization quotient of 0.5 to 1Ø
[0067] Optionally, the aluminum alloy material of the intermediate portion
has a
recrystallization quotient of no more than 0.25, or no more than 0.30, or no
more than 0.35,
or no more than 0.40, or no more than 0.45, or no more than 0.50, or no more
than 0.55, or no
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more than 0.60, or no more than 0.65. For example, the intermediate portion
may have a
recrystallization quotient of 0 to 0.65 or 0.01 to 0.65.
[0068] Optionally, the aluminum alloy article, when subjected to
bendability testing
according to Specification VDA 238-100, has a 13 angle of no more than 138 ,
or no more
than 137 , no more than 136 , no more than 135 , no more than 134 , no more
than 133 , no
more than 132 , or no more than 1310, such as between 100 and 142 .
[0069] Optionally, the aluminum alloy article, when subjected to
exfoliation corrosion
testing according to ASTM Test No. G34-01, has an exfoliation corrosion rating
of EA.
[0070]
Methods of Preparing Aluminum Alloy Articles
[0071] In certain aspects, the disclosed aluminum alloy articles are
products of a
disclosed method. Without intending to limit the scope of the inventions set
forth herein, the
properties of the aluminum alloy articles set forth herein are partially
determined by the
formation of certain microstructures during the preparation thereof.
[0072] In at least one aspect, the disclosure provides a method of making
an aluminum
alloy article, the method comprising: providing an aluminum alloy in a molten
state as a
molten aluminum alloy; casting the molten aluminum alloy to form an aluminum
alloy cast
product; homogenizing the aluminum alloy cast product to form a homogenized
aluminum
alloy cast product; rolling the homogenized aluminum alloy cast product to
form a first rolled
aluminum alloy product having a first thickness, wherein the rolling comprises
one or more
hot rolling passes and one or more cold rolling passes, wherein the one or
more hot rolling
passes precede the one or more cold rolling passes; annealing the first rolled
aluminum alloy
product at a temperature of not more than 50 C above the minimum
recrystallization
temperature of the aluminum alloy to form a first annealed aluminum product;
and rolling the
first annealed aluminum alloy product to form a second rolled aluminum product
having a
second thickness.
[0073] FIG. 1 provides an overview of a method of making an aluminum alloy
article.
The method of FIG. 1 begins at step 105 where an aluminum alloy 106 is cast to
form an
aluminum alloy cast product 107, such as an ingot or other cast product. At
step 110 the
aluminum alloy cast product 107 is homogenized to form a homogenized aluminum
alloy
cast product 111. At step 115, the homogenized aluminum alloy cast product 111
is
subjected to one or more hot rolling passes and one or more cold rolling
passes to form a first
rolled aluminum alloy product 112. At step 120, the first rolled aluminum
alloy product 112
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is annealed to form a first annealed aluminum alloy product 121. At step 125,
the first
annealed aluminum alloy product 121 is subjected to a second rolling process
to form a
second rolled aluminum product 126, which may correspond to an aluminum alloy
article.
Optionally, the second rolled aluminum product 126 is subjected to one or more
additional
forming or stamping processes to foim an aluminum alloy article.
Casting
[0074] The methods disclosed herein may comprise a step of casting a molten
aluminum
alloy to form an aluminum alloy cast product. In some embodiments, the molten
alloy may
be treated before casting. The treatment can include one or more of degassing,
inline fluxing,
and filtering. Aluminum alloy cast products can be formed using any casting
process
performed according to standards commonly used in the aluminum industry as
known to one
of ordinary skill in the art.
[0075] As a few non-limiting examples, the casting process can include a
Direct Chill
(DC) casting process or a Continuous Casting (CC) process. The continuous
casting system
can include a pair of moving opposed casting surfaces (e.g., moving opposed
belts, rolls or
blocks), a casting cavity between the pair of moving opposed casting surfaces,
and a molten
metal injector. The molten metal injector can have an end opening from which
molten metal
can exit the molten metal injector and be injected into the casting cavity. In
some
embodiments, the CC process may include, but is not limited to, the use of
twin-belt casters,
twin-roll casters, or block casters. In some embodiments, the casting process
is performed by
a CC process to form a cast product in the form of a billet, a slab, a shate,
a strip, and the like.
[0076] A clad layer in a cast product may be attached to a core layer in a
cast product to
form a cladded product by any means known to persons of ordinary skill in the
art. For
example, a clad layer can be attached to a core layer by direct chill co-
casting (i e , fusion
casting) as described in, for example, U.S. Patent Nos. 7,748,434 and
8,927,113;
by hot and cold rolling a
composite cast ingot as described in U.S. Patent No. 7,472,740;
or by roll bonding to achieve the required metallurgical bonding
between the core and the cladding. The initial dimensions and final dimensions
of the clad
aluminum alloy products described herein can be determined by the desired
properties of the
overall final product.
[0077] The roll bonding process can be carried out in different manners, as
known to
those of ordinary skill in the art. For example, the roll-bonding process can
include both hot
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rolling and cold rolling. Further, the roll bonding process can be a one-step
process or a
multi-step process in which the material is gauged down during successive
rolling steps.
Separate rolling steps can optionally be separated by other processing steps,
including, for
example, annealing steps, cleaning steps, heating steps, cooling steps, and
the like.
[0078] A cast product, such as an ingot, billet, slab, shate, strip, etc.,
can be processed by
any means known to those of ordinary skill in the art. Optionally, the
processing steps can be
used to prepare sheets. Such processing steps include, but are not limited to,
homogenization,
hot rolling, cold rolling, solution heat treatment, and an optional pre-aging
step, as known to
those of ordinary skill in the art. The processing steps can be suitably
applied to any cast
product, including, but not limited to, ingots, billets, slabs, strips,
plates, shates, etc., using
modifications and techniques as known to those of skill in the art. Specific
processing steps
may be used to prepare aluminum alloy articles with particular
recrystallization quotient
distributions, as described below.
[0079] In some cases, the casting process may impact the recrystallization
and reforming
that may occur during subsequent processing steps. For example, the
distribution of
dispersoid-forming elements in a cast product, such as an ingot, may impact
the ability of a
cast product to undergo recrystallization. By selectively segregating
dispersoid-forming
elements during the casting process, different regions of the cast products
and processed
products and articles may be more or less prone to undergo recrystallization.
Dispersoid
forming elements include, for example, Mn, Cr, Ti, Zr, and Sc, which may
precipitate out of
supersaturated solutions in the fonn of nano-scale precipitates, which may be,
for example,
from 10 nm in diameter to 30 nm in diameter. These precipitates may have sizes
that do not
promote recrystallization nucleation in the way that larger particles do.
Instead, these
particles may inhibit the motion of dislocations and grain boundaries such
that
recrystallization is inhibited. The volume or mass fraction of these
dispersoids may
determine or impact the specific recrystallization behavior in a cast product.
[0080] In large-scale castings, depletion or accumulation of alloying
elements can occur.
This is known as macrosegregation, which may be caused by the relative
movement of solid
and liquid phases which are of inherently different compositions. The center
of an ingot may
be particularly susceptible to macrosegregation, such as during casting For
example, this
area of an ingot may exhibit depletion of eutectic forming elements, with the
relative
depletion proportional to casting speed. This property is further elucidated
by Yu and
Granger in "Macrosegregation in Aluminum Alloy Ingot Cast by the
Semicontinuous Direct
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Chill (DC) Method, International Conference on Aluminum alloys ¨ Their
physical and
mechanical properties, Charlottesville, Virginia. Warley (UK): EMAS; 1986, p.
17-29.
[0081] Similarly, dispersoid forming elements may also be selectively
enriched in the
centerline, and the enrichment may also be enhanced by increasing the casting
speed. Thus,
by varying the casting speed, the distributions of dispersoid-forming elements
may be
optimized at the center of the ingot, which can impact the rate at which
recrystallization may
occur. For example, by increasing the casting speed in an ingot containing
dispersoid-
foi ming elements, their concentration at the center of the ingot may be
increased as compared
to slower casting rates. The enhanced dispersoid content in the corresponding
solidified ingot
can then be used during subsequent processing steps (e.g., rolling, annealing,
etc.) to impact
the rate of recrystallization at the center of a processed object. In this
way, casting can
impact the amount and rate of recrystallization at an intermediate portion
relative to surface
portions during subsequent rolling and annealing steps, for example.
Accordingly, methods
disclosed herein may optionally utilize a high-rate casting step, such as
greater than about 1.5
inches per minute (1PM), such as 1.5-10 IPM, 2.5-10 IPM, 3.5-10 IPM, or 4.5-10
IPM.
Stress Relieving
[0082] The methods disclosed herein can also optionally comprise a stress
relieving step,
which includes heating the aluminum alloy cast product prepared from an alloy
composition
described herein to attain a peak metal temperature (PMT) of at least 300 C
up to 420 C. In
some embodiments, the stress relieving is carried out at a temperature of 300
C, or 310 C,
or 320 C, or 330 C, or 340 C, or 350 C, or 360 C, or 370 C, or 380 C,
or 390 C, or
400 C, or 410 C, or 420 C. In general, the heating is carried out for a
period of at least 8
hours and up to, for example, 24 hours. In some embodiments, the heating is
carried out for 8
hours, or 9 hours, or 10 hours, or 11 hours, or 12 hours, or 13 hours, or 14
hours, or 15 hours,
or 16 hours, or 17 hours, or 18 hours, or 19 hours, or 20 hours, or 21 hours,
or 22 hours, or 23
hours, or 24 hours. During stress relieving, the microstructure of an aluminum
alloy cast or
rolled product may be modified, such as by a recrystallization process or
recovery process.
Homogenization
[0083] The homogenization step can include heating an aluminum alloy cast
product
prepared from an alloy composition described herein to attain a peak metal
temperature
(PMT) of at least 450 C (e.g., 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
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540 C, at least 550 C, at least 560 C, at least 570 C, or at least 580
C). For example, the
aluminum alloy product can be heated to a temperature of from 520 C to 580
C, from 530
C to 575 C, from 535 C to 570 C, from 540 C to 565 C, from 545 C to 560
C, from
530 C to 560 C, or from 550 C to 580 C. Optionally, the heating rate to
the PMT is 100
C/hour or less, 75 C/hour or less, 50 C/hour or less, 40 C/hour or less, 30
C/hour or less,
25 C/hour or less, 20 C/hour or less, or 15 C/hour or less. Optionally, the
heating rate to
the PMT is from 10 C/min to 100 C/min (e.g., 10 C/min to 90 C/min, 10
C/min to 70
C/min, 10 C/min to 60 C/min, from 20 C/min to 90 C/min, from 30 C/min to
80
C/min, from 40 C/min to 70 C/min, or from 50 C/min to 60 C/min).
[0084] In some instances, the aluminum alloy cast product is then allowed
to soak (i.e.,
held at a particular temperature, such as a PMT) for a period of time. In some
embodiments,
the aluminum alloy cast product is allowed to soak for up to 15 hours (e.g.,
from 30 minutes
to 6 hours, inclusively). For example, in some embodiments, the aluminum alloy
product is
soaked at a temperature of at least 450 C for 30 minutes, for 1 hour, for 2
hours, for 3 hours,
for 4 hours, for 5 hours, for 6 hours, for 7 hours, for 8 hours, for 9 hours,
for 10 hours, for 11
hours, for 12 hours, for 13 hours, for 14 hours, for 15 hours, or for any time
period in
between.
[0085] In some embodiments, the homogenization described herein can be
carried out in
a two-stage homogenization process. In some embodiments, the homogenization
process can
include the above-described heating and soaking steps, which can be referred
to as the first
stage, and can further include a second stage. In the second stage of the
homogenization
process, the temperature of the aluminum alloy cast product is increased to a
temperature
higher than the temperature used for the first stage of the homogenization
process. The
aluminum alloy cast product temperature can be increased, for example, to a
temperature at
least 5 C higher than the aluminum alloy cast product temperature during the
first stage of
the homogenization process. For example, the aluminum alloy cast product
temperature can
be increased to a temperature of at least 455 C (e.g., at least 460 C, at
least 465 C, or at
least 470 C). The heating rate to the second stage homogenization temperature
can be 5
C/hour or less, 3 C/hour or less, or 2.5 C/hour or less. The aluminum alloy
cast product is
then allowed to soak for a period of time during the second stage. In some
embodiments, the
aluminum alloy cast product is allowed to soak for up to 10 hours (e.g., from
30 minutes to
hours, inclusively). For example, the aluminum alloy cast product can be
soaked at the
temperature of at least 455 C for 30 minutes, for 1 hour, for 2 hours, for 3
hours, for 4 hours,
for 5 hours, for 6 hours, for 7 hours, for 8 hours, for 9 hours, or for 10
hours. In some
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embodiments, following homogenization, the aluminum alloy cast product is
allowed to cool
to room temperature in the air.
Hot Rolling
[0086] Following the homogenization step, one or more hot rolling passes
may be
performed. In certain cases, the aluminum alloy products are laid down and hot
rolled at a
temperature ranging from 250 C to 550 C (e.g., from 300 C to 500 C, or
from 350 C to
450 C).
[0087] In certain embodiments, the aluminum alloy product is hot rolled to
a 4 mm to 15
mm thick gauge (e.g., from 5 mm to 12 mm thick gauge), which is referred to as
a shate. For
example, the aluminum alloy product can be hot rolled to a 15 mm thick gauge,
a 14 mm
thick gauge, a 13 mm thick gauge, a 12 mm thick gauge, a 11 mm thick gauge, a
10 mm thick
gauge, a 9 mm thick gauge, a 8 mm thick gauge, a 7 mm thick gauge, a 6 mm
thick gauge, or
a 5 mm thick gauge, or anywhere in between.
[0088] In certain other embodiments, the aluminum alloy product can be hot
rolled to a
gauge greater than 15 mm thick (i.e., a plate). For example, the aluminum
alloy product can
be hot rolled to a 25 mm thick gauge, a 24 mm thick gauge, a 23 mm thick
gauge, a 22 mm
thick gauge, a 21 mm thick gauge, a 20 mm thick gauge, a 19 mm thick gauge, a
18 mm thick
gauge, a 17 mm thick gauge, or a 16 mm thick gauge, or any suitable gauge in
between or
above 25 mm thick.
[0089] In other cases, the aluminum alloy product can be hot rolled to a
gauge no more
than 4 mm (i.e., a sheet). In some embodiments, the aluminum alloy product is
hot rolled to a
1 mm to 4 mm thick gauge, which is referred to as a sheet. For example, the
aluminum alloy
product can be hot rolled to a 4 mm thick gauge, a 3 mm thick gauge, a 2 mm
thick gauge, or
a 1 mm thick gauge, or anywhere in between.
Cold Rolling and Annealing and Further Rolling
[0090] Following the hot rolling, one or more cold rolling passes may be
performed. In
certain embodiments, the rolled product from the hot rolling step (e.g., the
plate, shate, or
sheet) can be cold rolled to a thin gauge shate or sheet. In some embodiments,
this thin-
gauge shate or sheet is cold rolled to have a thickness (i.e., a first
thickness) ranging from 1.0
mm to 12.0 mm, or from 2.0 mm to 8.0 mm, or from 3.0 mm to 6.0 mm, or from 4.0
mm to
5.0 mm. In some embodiments, this thin-gauge shate or sheet is cold rolled to
have a
thickness 12.0 mm, 11.9 mm, 11.8 mm, 11.7 mm, 11.6 mm, 11.5 mm, 11.4 mm, 11.3
mm,
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11.2 mm, 11.1 mm, 11.0 mm, 10.9 mm, 10.8 mm, 10.7 mm, 10.6 mm, 10.5 mm, 10.4
mm,
10.3 mm, 10.2 mm, 10.1 mm, 10.0 mm, 9.9 mm, 9.8 mm, 9.7 mm, 9.6 mm, 9.5 mm,
9.4 mm,
9.3 mm, 9.2 mm, 9.1 mm, 9.0 mm, 8.9 mm, 8.8 mm, 8.7 mm, 8.6 mm, 8.5 mm, 8.4
mm, 8.3
mm, 8.2 mm, 8.1 mm, 8.0 mm, 7.9 mm, 7.8 mm, 7.7 mm, 7.6 mm, 7.5 mm, 7.4 mm,
7.3 mm,
7.2 mm, 7.1 mm, 7.0 mm, 6.9 mm, 6.8 mm, 6.7 mm, 6.6 mm, 6.5 mm, 6.4 mm, 6.3
mm, 6.2
mm, 6.1 mm, 6.0 mm, 5.9 mm, 5.8 mm, 5.7 mm, 5.6 mm, 5.5 mm, 5.4 mm, 5.3 mm,
5.2 mm,
5.1 mm, 5.0 mm, 4.9 mm, 4.8 mm, 4.7 mm, 4.6 mm, 4.5 mm, 4.4 mm, 4.3 mm, 4.2
mm, 4.1
mm, 4.0 mm, 3,9 mm, 3.8 mm, 3.7 mm, 3.6 mm, 3.5 mm, 3.4 mm, 3.3 mm, 3.2 mm,
3.1 mm,
3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1
mm, 2.0
mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, or
1.0
mm, or anywhere in between.
[0091] In some embodiments, the one or more cold rolling passes reduce the
thickness of
rolled aluminum product by at least 30%, or at least 35%, or at least 40%, or
at least 45%, or
at least 50%, or at least 55%, or at least 60%, or at least 65%, or at least
70%. In some
embodiments, the one or more cold rolling passes reduce the cast product to a
thickness (i.e.,
a first thickness) of no more than 10 mm, or no more than 9 mm, or no more
than 8 mm, or
no more than 7 mm, or no more than 6 mm, or no more than 5 mm.
[0092] Following one or more cold rolling passes, annealing may be
performed. This can
also be referred to as an intermediate annealing or inter-annealing, as it is
performed in the
middle of the rolling process, as, in some embodiments, one or more additional
rolling passes
are carried out after the annealing.
[0093] The annealing step can include heating the rolled aluminum product
from room
temperature to a temperature from 380 C to 500 C (e.g., from 385 C to 495
C, from 390
C to 490 C, from 395 C to 485 C, from 400 C to 480 C, from 405 C to 475
C, from
410 C to 470 C, from 415 C to 465 C, from 420 C to 460 C, from 425 C to
455 C,
from 430 C to 460 C, from 380 C to 450 C, from 405 C to 475 C, or from
430 C to
500 C).
[0094] This intermediate annealing step can, for example, lead to certain
beneficial
texture features in the resulting article. In particular, the intermediate
annealing assists in the
formation of the recrystallized microstructure on surface of the article and
the recovered
and/or unrecrystallized structure in the middle of the article. In some
examples, the texture
on surface of the article will be dominated by recrystallization components,
including cube,
cube ND, and cube RD, rather than deformation type components, such as Bs, S,
and Cu.
Therefore, the bending performance of the article is improved without reducing
the strength.
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[0095] The plate, shate, or sheet can soak at the intermediate annealing
temperature for a
period of time. In one non-limiting example, the plate, shate, or sheet is
allowed to soak for
up to approximately 2 hours (e.g., from about 15 to about 120 minutes,
inclusively). For
example, the plate, shate, or sheet can be soaked at the temperature of from
about 400 C to
about 500 C for 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes,
40 minutes, 45
minutes, 50 minutes, 55 minutes, 60 minutes, 65 minutes, 70 minutes, 75
minutes, 80
minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, 105 minutes, 110
minutes, 115
minutes, or 120 minutes, or anywhere in between.
[0096] In some embodiments, the intermediate annealing of the rolled
aluminum alloy
product is carried out at a temperature of no more than 45 C, or no more than
40 C, or no
more than 35 C, or no more than 30 C, or no more than 25 C, or no more than
20 C, or no
more than 15 C, or no more than 10 C, above the minimum recrystallization
temperature of
the aluminum alloy. In some embodiments, the intermediate annealing of the
rolled
aluminum alloy product is carried out at a temperature above the minimum
recrystallization
temperature of the aluminum alloy for no more than 3.0 hours, or no more than
2.5 hours, or
no more than 2.0 hours, or no more than 1.5 hours, or no more than 1.0 hours.
[0097] Optionally, the intermediate annealing may comprise multiple
annealing sub-
steps. For example, in some embodiments, the annealing is carried out at a
first temperature
above the minimum recrystallization temperature for a first period of time and
at a second
temperature above the minimum recrystallization temperature for a second
period of time.
For example, the first temperature above the minimum recrystallization
temperature may be
greater than the second temperature above the minimum recrystallization
temperature.
Annealing may, for example, subject the surface portions to higher temperature
annealing
conditions at earlier times than the intermediate portion. By using a two (or
more) step
intermediate annealing process in which the temperature at the second step is
lower than that
at the first step, the surface portions of the rolled aluminum alloy product
may be subjected to
recrystallization conditions for longer periods of time than the intermediate
portion. This
may also occur in a single step intermediate annealing process in which a
single annealing
temperature is used, but the effect may be more pronounced in a multiple step
annealing
process.
[0098] Optionally, following the intermediate annealing, further rolling is
performed,
such as cold rolling. In some embodiments, one or more additional cold rolling
passes are
performed. This additional rolling brings the aluminum alloy product to a
final thickness
(i.e., a second thickness). In some embodiments, the final thickness ranges
from 0.1 mm to
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4.0 mm. In some embodiments, the final thickness is 4.0 mm, 3.9 mm, 3.8 mm,
3.7 mm, 3.6
mm, 3.5 mm, 3.4 mm, 3.3 mm, 3.2 mm, 3.1 mm, 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm,
2.6 mm,
2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm, 2.0 mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6
mm, 1.5
mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm,
0.5 mm,
0.4 mm, 0.3 mm, 0.2 mm, or 0.1 mm. In some further such embodiments, the final
thickness
is no more than 4.0 mm, or no more than 3.5 mm, or no more than 3.0 mm, or no
more than
2.5 mm, or no more than 2.0 mm, or no more than 1.5 mm, or no more than 1.0
mm, or no
more than 0.5 mm, or no more than 0.3 mm, or no more than 0.1 mm.
Finishing Steps
[0099] Optionally, following the intermediate annealing and/or the
additional rolling,
additional finishing steps can be carried out, including, but not limited to,
one or more of
solutionizing, quenching, ageing, and coiling.
[0100] In some embodiments, a solution heat treatment step can be carried
out. The
solution heat treatment step can include heating the aluminum alloy product
from room
temperature to a temperature of from 430 C to 500 C. For example, the
solution heat
treatment step can include heating the aluminum alloy product from room
temperature to a
temperature of from 440 C to 500 C, from 460 C to 500 C, or from 480 C to
490 C. In
some examples, the heating rate for the solution heat treatment step can be
from 250 C/hour
to 350 C/hour (e.g., 250 C/hour, 255 C/hour, 260 C/hour, 265 C/hour, 270
C/hour, 275
C/hour, 280 C/hour, 285 C/hour, 290 C/hour, 295 C/hour, 300 C/hour, 305
C/hour,
310 C/hour, 315 C/hour, 320 C/hour, 325 C/hour, 330 C/hour, 335 C/hour,
340
C/hour, 345 C/hour, or 350 C/hour).
[0101] In some embodiments, the aluminum alloy product can then be cooled
to a
temperature of about 25 C at a quench speed that can vary between about 50
C/s to 400
C/s in a quenching step that is based on the selected gauge. For example, the
quench rate
can be from about 50 C/s to about 375 C/s, from about 60 C/s to about 375
C/s, from
about 70 C/s to about 350 C/s, from about 80 C/s to about 325 C/s, from
about 90 C/s to
about 300 C/s, from about 100 C/s to about 275 C/s, from about 125 C/s to
about 250
C/s, from about 150 C/s to about 225 C/s, or from about 175 C/s to about
200 C/s.
[0102] In the quenching step, the aluminum alloy product is rapidly
quenched with a
liquid (e.g., water) and/or gas or another selected quench medium. In certain
aspects, the
aluminum alloy product can be rapidly quenched with water. In certain
embodiments, the
aluminum alloy product is quenched with air.
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[0103] In some embodiments, the aluminum alloy product can be artificially
aged for a
period of time to result in the T6 or T7 temper. In certain embodiments, the
aluminum alloy
product can be artificially aged (AA) at about 100 C to 225 C (e.g., 100 C,
105 C, 110
C, 115 C 120 C 125 C 130 C 135 C 140 C 145 C 150 C 155 C 160 C 165
C, 170 C, 175 C, 180 C, 185 C, 190 C, 195 C, 200 C, 205 C, 210 C, 215
C, 220
C, or 225 C) for a period of time. Optionally, the aluminum alloy product can
be cold
worked and artificially aged for a period from about 15 minutes to about 48
hours (e.g., 15
minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7
hours, 8 hours, 9
hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours,
17 hours, 18
hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours,
26 hours, 27
hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours,
35 hours, 36
hours, 37 hours, 38 hours, 39 hours, 40 hours, 41 hours, 42 hours, 43 hours,
44 hours, 45
hours, 46 hours, 47 hours, or 48 hours, or anywhere in between).
[0104] In some embodiments, an annealing step during or after production
can also be
applied to produce the aluminum alloy product in a coil form for improved
productivity or
formability. For example, an alloy in coil form can be supplied in the 0
temper, using a hot
or cold rolling step and an annealing step following the hot or cold rolling
step. Forming may
occur in 0 temper, which is followed by solution heat treatment, quenching and
artificial
aging/paint baking
[0105] In certain aspects, to produce an aluminum alloy product in coil
form and with
high founability compared to F temper, an annealing step can be applied to the
coil. Without
intending to limit the invention, the purpose for the annealing and the
annealing parameters
may include (1) releasing the work-hardening in the material to gain
formability; (2)
recrystallizing or recovering the material without causing significant grain
growth; (3)
engineering or converting texture to be appropriate for forming and for
reducing anisotropy
during formability; and (4) avoiding the coarsening of pre-existing
precipitation particles.
[0106] In one or more aspects, the disclosure provides aluminum alloy
articles formed by
the processes set forth above, or any embodiments thereof
Articles of Manufacture
[0107] The disclosure provides an article of manufacture, which is
comprised of an
aluminum alloy product disclosed herein. In some embodiments, the article of
manufacture
is comprised of a rolled aluminum alloy product. Examples of such articles of
manufacture
include, but are not limited to, an automobile, a truck, a trailer, a train, a
railroad car, an
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airplane, a body panel or part for any of the foregoing, a bridge, a pipeline,
a pipe, a tubing, a
boat, a ship, a storage container, a storage tank, a an article of furniture,
a window, a door, a
railing, a functional or decorative architectural piece, a pipe railing, an
electrical component,
a conduit, a beverage container, a food container, or a foil.
[0108] In some other embodiments, the aluminum alloy articles disclosed
herein can be
used in automotive and/or transportation applications, including motor
vehicle, aircraft, and
railway applications, or any other desired application. In some examples, the
aluminum alloy
products disclosed herein can be used to prepare motor vehicle body part
products, such as
bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-
pillars, B-
pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods,
outer hoods, or
trunk lid panels. The aluminum alloys and methods described herein can also be
used in
aircraft or railway vehicle applications, to prepare, for example, external
and internal panels.
[0109] In some other embodiments, the aluminum alloy articles disclosed
herein can be
used in electronics applications. For example, the aluminum alloy products
disclosed herein
can also be used to prepare housings for electronic devices, including mobile
phones and
tablet computers. In some examples, the alloys can be used to prepare housings
for the outer
casing of mobile phones (e.g., smart phones) and tablet bottom chassis.
[0110] In some other embodiments, the aluminum alloy articles disclosed
herein can be
used in industrial applications. For example, the aluminum alloy products
disclosed herein
can be used to prepare products for the general distribution market.
[0111] In some other embodiments, the aluminum alloy articles disclosed
herein can be
used as aerospace body parts. For example, the aluminum alloy articles
disclosed herein can
be used to prepare structural aerospace body parts, such as a wing, a
fuselage, an aileron, a
rudder, an elevator, a cowling, or a support. In some other embodiments, the
aluminum alloy
articles disclosed herein can be used to prepare non-structural aerospace body
parts, such as a
seat track, a seat frame, a panel, or a hinge.
[0112] The following examples serve to further illustrate certain
embodiments of the
present disclosure without, at the same time, however, constituting any
limitation thereof. On
the contrary, it is to be clearly understood that resort may be had to various
embodiments,
modifications and equivalents thereof which, after reading the description
herein, may
suggest themselves to those of ordinary skill in the art without departing
from the spirit of the
disclosure.
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EXAMPLE 1 - Alloy Compositions
[0113] Six aluminum alloys (Al/Alloy Al, A2/Alloy A2, A3/Alloy A3, A4/Alloy
A4,
A5/Alloy A5, and A6/Alloy A6) were prepared, whose elemental composition is
set forth in
Table 3 below. The elemental compositions are provided in weight percentages.
Table 3
Alto
Cr Cu Fe Ga Mg Mn Ni Si Ti V Zn Zr Al
0.0 1.1 0.1 2.2 0.0 0.00 0.1 0.0 0.0 7.9 0.14 bal
Al 0.01
3 3 8 5 3 3 0 5 1 2
A 0.1 1.1 0.1 2.2 0.0 0.00 0.0 0.0 0.0 7.8 0.14 bal
2 0.01
0 2 8 4 4 3 9 5 1 6
A3
0.0 1.7 0.1 0 01 2.5 0.0 0.00 0.1 0.0
0.0 5.5 0.14 bal
.
4 0 9 6 5 3 0 4 1 1
A4 0.0 1.7 0.2 0.01 2.6 0.0 0.00 0.0 0.0 0.0 5.3 0.14 bal
4 7 0 7 4 3 8 4 1 8
A5 0.0 1.2 0.1 0.01 2.3 0.0 0.00 0.0 0.0 0.0 7.6 0.13 bal
3 4 9 0 1 3 3 8 5 1 4
A6 0.2 1.6 0.1 n/a 2.7 0.0 n/a 0.0 0.0 n/a 5.9 0.00 bal
4 3 7 5 2 4 2 4 1 .
All expressed in wt. %.
n/a = not present or present in trace quantities (<0.0005 wt. %)
EXAMPLE 2 - Manufacture of Aluminum Alloy Sheet
[0114] The test aluminum alloy sheets with chemical composition
corresponding to
Alloys A1-A6 from Table 3 (Example 1), were cast by Direct Chill (DC) casting.
All were
stress relieved and homogenized, and subsequently hot-rolled to a hot band
having a gauge of
10.5 mm. Each was then subjected to cold rolling. For each, the hot band went
through 2
passes of cold rolling from 10.5 mm to 6 mm and 4 mm, respectively.
[0115] Inter-annealing of Alloys Al, A2 and A3 was performed at 4.0 mm
gauge, with a
50 C/hr ramping rate to 410 C, soaked for 60 minutes, then furnace cooled to
350 C and
soaked for 1200 minutes. The coils were allowed to cool to room temperature in
air. A final
cold rolling was then performed on these three samples, Alloys Al, A2, and A3.
The coils
were cold rolled to final gauge of 2.0 mm with 1 pass.
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[0116] For Alloys A4, A5, and A6, the hot band of 10.5 mm gauge was cold
rolled to 6.0
mm, then to 4.0 mm, then to 2.8 mm, and then to 2.0 mm, without any inter-
annealing steps.
[0117] Solution heat treatment of test blanks of samples of Alloys Al-A6
were carried
out, where the samples were heated up using a furnace to a PMT of 480 C and
soaked for 5
minutes, before being taken out of the furnace and quenched in warm water at
55 C at a
quench rate of around 350 C/sec. Artificial aging of samples of Alloys Al-A6
was carried
out using a furnace at 125 C and soaked for 24 hours to bring the samples to
T6 temper.
EXAMPLE 3 ¨ Optical Microscopy and Scanning Electron Micrographs with EBSD
[0118] Optical microscopy (OM) was carried out for aluminum alloy sheets
made of the
alloys of Example 1, such as according to Example 2. FIG. 2 shows an optical
micrograph
(OM) of a cross-section of a sample of Alloy Al that was lab rolled with inter-
annealing, and
which shows recovered and/or unrecrystallized microstructure through the
thickness of the
sample. FIG. 3A shows an optical micrograph (OM) of a cross-section of a
sample of Alloy
Al that was plant rolled with inter-annealing. The sample of Alloy Al of FIG.
3A includes a
first surface portion 205, an intermediate portion 210, and a second surface
portion 215.
[0119] "Plant Rolled" samples were cold-rolled according to standard plant
cold rolling
processes. "Lab Rolled" samples were cold-rolled in a laboratory setting from
10.5 mm to
2.0 mm by conducting 17 different passes, each of which reduced the thickness
by about 0.5
mm.
[0120] FIG. 3B shows a surface portion from FIG. 3A, showing recrystallized
microstructure, corresponding to at least a portion of first surface portion
205 or second
surface portion 215. In FIG. 3B, the grain structure of the sample can be
seen, with
individual grains not spread significantly in the surface portion, indicating
that the crystal
structure has been recovered and/or is unrecrystallized by the inter-annealing
process. FIG.
3C shows nine modified reduced-size versions of FIG. 3B, generated by reducing
FIG. 3B to
9 individual colors in order to highlight various colors shown in FIG. 3B as
black. For
example, in panel 1, dark purple features of FIG. 3B are depicted in black. In
panel 2, light
purple features of FIG. 3B are depicted in black. In panel 3, black features
of FIG. 3B are
depicted in black. In panel 4, light blue features of FIG. 3B are depicted in
black. In panel 5,
dark blue features of FIG. 3B are depicted in black. In panel 6, orange
features of FIG. 3B
are depicted in black. In panel 7, medium blue features of FIG. 3B are
depicted in black. In
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panel 8, yellow features of FIG. 3B are depicted in black. In panel 9, pink
features of FIG.
3B are depicted in black.
[0121] FIG. 3D shows a center section from FIG. 3A, showing recovered
and/or
unrecrystallized microstructure, corresponding to at least a portion of
intermediate portion
210. In FIG. 3D, the remnants of grains that were significantly spread during
the initial
rolling process can be seen. The remnants do not all recrystallize during the
inter-annealing
process and many regions remain spread in the center portion, reflecting the
recovered and/or
unrecrystallized nature of the intermediate portion 210. FIG. 3E shows nine
modified
reduced-size versions of FIG 3D, generated by reducing FIG. 3D to 9 individual
colors in
order to highlight various colors shown in FIG. 3D as black. For example, in
panel 1, dark
purple features of FIG. 3D are depicted in black. In panel 2, light purple
features of FIG. 3D
are depicted in black. In panel 3, black features of FIG. 3D are depicted in
black. In panel 4,
light blue features of FIG. 3D are depicted in black. In panel 5, dark blue
features of FIG. 3D
are depicted in black. In panel 6, orange features of FIG. 3D are depicted in
black. In panel
7, medium blue features of FIG. 3D are depicted in black. In panel 8, yellow
features of FIG
3D. are depicted in black. In panel 9, pink features of FIG 3D. are depicted
in black.
[0122] FIG. 4A shows an optical micrograph of a sample of Alloy A5 that was
plant
rolled without inter-annealing during the cold rolling process, showing spread
grains as
horizontal structures in FIG 4A FIG. 4B shows a section from the center
portion in FIG. 4A
corresponding to at least a portion of the intermediate portion, showing
recovered and/or
unrecrystallized microstructure. FIG. 4C shows a surface portion from FIG. 4A,
showing
recrystallized microstructure.
[0123] Electron backscattering diffraction (EBSD) disorientation mapping
was carried
out on certain samples. Mapping of a cross-section of samples of Alloy Al that
were rolled
to a final gauge and finished with a T6 temper is shown in FIGs. 5A, 5B, and
5C. The low
angle boundaries (2-15) are marked as darker-color horizontal lines, while the
medium to
high angle boundaries (>15) are marked as lighter-color horizontal lines. FIG.
5A provides
mapping for an Alloy Al sample that was lab rolled, without inter-annealing
during the cold
rolling process, which has a uniform microstructure with recovered and/or
unrecrystallized
microstructure through the whole thickness, while FIG. 5B provides mapping for
an Alloy
Al sample that was plant rolled, with inter-annealing during the cold rolling
process, which
shows the recrystallization microstructure near the surface and recovered
and/or
unrecrystallized microstructure in the center (i.e., intermediate portion).
FIG. 5C shows
mapping for an Alloy AS sample that was plant rolled, without inter-annealing
during the
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cold rolling process, which has a microstructure between that shown in FIG. 5A
and FIG. 5B.
Quantitative results from these images are presented in Table 4 below.
EXAMPLE 4 ¨ Recrystallization Quotient
[0124] The recrystallization quotient (RQ) was calculated using the EBSD
measurements
described in Example 3. Orientation mapping was performed on a square grid
across a cross-
sectionally cut area. The mapped area was divided into three equally sized
areas spanning the
thickness of the sheet, and the recrystallization quotient was calculated for
each area. Table 4
reports the values of the recrystallization quotient for each of the samples
described in
Example 3. The "Surface RQ" refers to RQ for the two surface areas (i.e.,
surface portions),
"Center RQ" refers to the RQ for the center area (i.e., intermediate portion),
and the "Overall
RQ" refers to the RQ across the thickness of the entire sample. Note that "IA"
refers to inter-
annealing performed during the cold rolling process.
Table 4
Sample Overall RQ Surface RQ Center RQ
Alloy Al, Lab Processed 0.512 0.532 0.467
Alloy Al, Plant Rolled without IA 0.684 0.819 0.553
Alloy AS, Plant Rolled with IA 0.758 0.871 0.592
[0125] The "Plant Rolled" samples were cold-rolled according to standard
plant cold
rolling processes. The "Lab Rolled" sample was cold-rolled in a laboratory
setting from 10.5
mm to 2.0 mm by conducting 17 different passes, each of which reduced the
thickness by
about 0.5 mm.
EXAMPLE 5¨ Bending
[0126] The bendability was measured for samples of aluminum alloy sheets
prepared
according to Example 2. The bendability for the samples was measured according
to Spec
VDA-238-100. The samples were tested in the longitudinal and transverse
directions in T6
temper. FIG. 6 shows the 3-point bend results of Alloys Al, A2, AS (without
IA) and a
sample of AA7075 sheet. The angle reported was 13 angle, thus the lower the
better. For
Alloys Al and A2, the left bar is for the longitudinal direction and the right
bar is for the
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transverse direction. For Alloys A5 and the AA7076 sample, only the
longitudinal direction
is shown. All were tested in the T6 temper.
EXAMPLE 6 ¨ Exfoliation Corrosion
[0127] The exfoliation corrosion (EXCO) was measured for certain aluminum
alloy
sheets prepared according to Example 2. The EXCO was measured according to the
procedure set forth in ASTM-G34, which involved the continuous immersion of
test
materials in a solution containing 4 M sodium chloride, 0.5 M potassium
nitrate, and 0.1 M
nitric acid at 25 3 C. The susceptibility to exfoliation was determined by
visual
examination, with performance ratings established by reference to standard
photographs (see
the G34 test procedure). Visual examination was conducted, along with
longitudinal cross-
section metallographic examination. FIGs. 7A-7E show photographs of tested
aluminum
alloy sheets, as identified in Table 5 below.
Table 5
Sample Figure No.
Alloy Al, Plant Processed without IA 7A
Alloy A2, Plant Processed without IA 7B
Alloy A6, Plant Processed without IA 7C
Alloy Al, Lab Processed with IA 7D
Alloy A2, Lab Processed with IA 7E
EXAMPLE 7 ¨ Yield Strength
[0128] The yield strength was measured for certain aluminum alloy sheets
prepared
according to Example 2. The yield strength was tested in accordance to ASTM E8
with 2"
standard gauge length. FIG. 8 shows the results of yield strength testing on
certain samples,
where L, T, and D stand for longitudinal, transverse and diagonal,
respectively, with respect
to rolling direction. For Alloy Al, Alloy A2, Alloy A3, and Alloy A6, the
three bars show
the results of testing in the longitudinal, transverse, and diagonal
directions, respectively,
from left to right. For Alloy AS, the two bars show the results of testing in
the longitudinal
and transverse directions, respectively, from left to right.
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ILLUSTRATIONS
[0129] As used below, any reference to a series of illustrations is to be
understood as a
reference to each of those examples disjunctively.
[0130] Illustration 1 is an aluminum alloy article, which is comprised of
an aluminum
alloy material and further comprises a first surface portion; a second surface
portion opposing
the first surface portion; and an intermediate portion between the first
surface portion and the
second surface portion; wherein the first surface portion comprises a rolled
surface and the
second surface portion comprises a rolled surface; and wherein the aluminum
alloy material
of the first surface portion and the second surface portion have a higher
recrystallization
quotient than the aluminum alloy material of the intermediate portion.
[0131] Illustration 2 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the aluminum alloy material is a 5xxx series aluminum
alloy, a 6xxx
series aluminum alloy, or a 7xxx series aluminum alloy.
[0132] Illustration 3 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the aluminum alloy material is a 7xxx series aluminum
alloy.
[0133] Illustration 4 is the aluminum alloy material of any preceding or
subsequent
illustration, wherein the aluminum alloy material is an aluminum alloy
selected from the
group consisting of AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075,
AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025,
AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003,
AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116,
AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034,
AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A,
AA7149,7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250,
AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168,
AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185,
AA7090, AA7093, AA7095, and AA7099.
[0134] Illustration 5 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material comprises: from
4.0 to 15.0
percent by weight Zn; from 0.1 to 3.5 wt. % Cu; from 1.0 to 4.0 wt. % Mg; from
0.05 to 0.50
wt. % Fe; from 0.05 to 0.30 wt. % Si; from 0.01 to 0.50 wt. /c. Zr; up to
0.25 wt. % Mn; up to
0.20 wt. % Cr; up to 0.15 wt. % Ti; and up to 0.15 wt. c/1/0 impurities; with
the remainder being
Al.
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[0135] Illustration 6 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the aluminum alloy material comprises: from 5.6 to 9.3
wt. % Zn; from
0.2 to 2.6 wt. % Cu; from 1.4 to 2.8 wt. % Mg; from 0.10 to 0.35 wt. % Fe;
from 0.05 to 0.20
wt. % Si; from 0.05 to 0.25 wt. % Zr; up to 0.05 wt. % Mn; up to 0.10 wt. /0
Cr; up to 0.05
wt. % Ti; and up to 0.15 wt. % impurities; with the remainder being Al.
[0136] Illustration 7 is the aluminum alloy article of any preceding or
subsequent
illustration, further comprising up to 0.10 wt. % of one or more elements
selected from the
group consisting of Mo, Nb, Be, B, Co, Sn, Sr, V, In, Hf, Ag, Sc, and Ni.
[0137] Illustration 8 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, further comprising up to 0.10 wt. % of one or more
elements selected
from the group consisting of Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho,
Er, Tm, Yb,
and Lu.
[0138] Illustration 9 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the rolled surface of the first surface
portion is formed by a
process that comprises cold rolling.
[0139] Illustration 10 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the rolled surface of the second surface
portion is formed by
a process that comprises cold rolling.
[0140] Illustration 11 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy article is a rolled
aluminum alloy shate
or a rolled aluminum alloy sheet.
[0141] Illustration 12 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the aluminum alloy article has a thickness of no more
than 15 mm, or no
more than 14 mm, or no more than 13 mm, or no more than 12 mm, or no more than
11 mm,
or no more than 10 mm, or no more than 9 mm, or no more than 8 mm, or no more
than 7
mm, or no more than 6 mm, or no more than 5 mm, or no more than 4 mm, or no
more than 3
mm, or no more than 2 mm, or no more than 1 mm, or no more than 0.5 mm, or no
more than
0.3 mm, or no more than 0.1 mm.
[0142] Illustration 13 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the first surface portion extends from the
surface of the first
surface portion to a depth of no more than 40.0%, or no more than 35.0%, or no
more than
33.3%, or no more than 30.0%, or no more than 25.0%, or no more than 20.0%, or
no more
than 15.0%, or no more than 10.0%, of the thickness of the aluminum alloy
article.
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[0143] Illustration 14 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the second surface portion extends from the
surface of the
second surface portion to a depth of no more than 40.0%, or no more than
35.0%, or no more
than 33.3%, or no more than 30.0%, or no more than 25.0%, or no more than
20.0%, or no
more than 15.0%, or no more than 10.0%, of the thickness of the aluminum alloy
article.
[0144] Illustration 15 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the intermediate portion extends from the
depth of the first
surface portion to the depth of the second surface portion.
[0145] Illustration 16 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the intermediate portion lies between the
depth of the first
surface portion and the depth of the second surface portion, includes the
midpoint in the
thickness between the depth of the first surface portion and the depth of the
second surface
portion, and includes no more than 10.0%, or no more than 20.0%, or no more
than 30.0%, or
no more than 40.0%, or no more than 50.0%, or no more than 60.0%, or no more
than 70.0%,
or no more than 80.0%, or no more than 90.0%, or no more than 95.0%, or no
more than
97.0%, or no more than 99.0%, of the thickness between the depth of the first
surface portion
and the depth of the second surface portion.
[0146] Illustration 17 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the midpoint in the thickness between the depth of the
first surface
portion and the depth of the second surface portion lies at midpoint in the
thickness of the
intermediate portion.
[0147] Illustration 18 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material of the second
surface portion
has a higher recrystallization quotient than the aluminum alloy material of
the intermediate
portion.
[0148] Illustration 19 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material of the first
surface portion has a
recrystallization quotient that is higher, such as at least 0.01 higher, or at
least 0.03 higher, or
at least 0.05 higher, or at least 0.07 higher, or at least 0.10 higher, or at
least 0.15 higher, or at
least 0.20 higher, or at least 0.25 higher, than the recrystallization
quotient of the aluminum
alloy material of the intermediate portion.
[0149] Illustration 20 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material of the second
surface portion
has a recrystallization quotient that is higher, such as at least 0.01 higher,
or at least 0.03
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higher, or at least 0.05 higher, or at least 0.07 higher, or at least 0.10
higher, or at least 0.15
higher, or at least 0.20 higher, or at least 0.25 higher, than the
recrystallization quotient of the
aluminum alloy material of the intermediate portion.
[0150] Illustration 21 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material of the first
surface portion has a
recrystallization quotient of at least 0.50, or at least 0.55, or at least
0.60, or at least 0.65, or at
least 0.70, or at least 0.75, or at least 0.80, or at least 0.85, or at least
0.90.
[0151] Illustration 22 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material of the second
surface portion
has a recrystallization quotient of at least 0.50, or at least 0.55, or at
least 0.60, or at least
0.65, or at least 0.70, or at least 0.75, or at least 0.80, or at least 0.85,
or at least 0.90.
[0152] Illustration 23 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy material of the
intermediate portion has a
recrystallization quotient of no more than 0.25, or no more than 0.30, or no
more than 0.35,
or no more than 0.40, or no more than 0.45, or no more than 0.50, or no more
than 0.55, or no
more than 0.60, or no more than 0.65.
[0153] Illustration 24 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy article, when subjected to
bendability
testing according to Specification VDA 238-100, has af3 angle of no more than
138 , or no
more than 137 , no more than 136 , no more than 135 , no more than 134 , no
more than
133 , no more than 132 , or no more than 131 .
[0154] Illustration 25 is the aluminum alloy article of any one of any
preceding or
subsequent illustration, wherein the aluminum alloy article, when subjected to
exfoliation
corrosion testing according to ASTM Test No. G34-01, has a exfoliation
corrosion rating of
EA.
[0155] Illustration 26 is a method of making an aluminum alloy article, the
method
comprising providing an aluminum alloy, wherein the aluminum alloy is provided
in a
molten state as a molten aluminum alloy; casting the molten aluminum alloy to
form an
aluminum alloy cast product; homogenizing the aluminum alloy cast product to
form a
homogenized aluminum alloy cast product; rolling the homogenized aluminum
alloy cast
product to form a first rolled aluminum alloy product having a first
thickness, wherein the
rolling comprises one or more hot rolling passes and one or more cold rolling
passes, wherein
the one or more hot rolling passes precede the one or more cold rolling
passes; annealing the
first rolled aluminum alloy product at a temperature of not more than 50 C
above the
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minimum recrystallization temperature of the aluminum alloy to folin a first
annealed
aluminum product; and rolling the first annealed aluminum alloy product to
form a second
rolled aluminum product having a second thickness.
[0156] Illustration 27 is the method of any preceding or subsequent
illustration, wherein
the aluminum alloy is a 5xxx series aluminum alloy, a 6xxx series aluminum
alloy, or a 7xxx
series aluminum alloy.
[0157] Illustration 28 is the method of any preceding or subsequent
illustration, wherein
the aluminum alloy is a 7xxx series aluminum alloy.
[0158] Illustration 29 is the method of any preceding or subsequent
illustration any one of
any preceding or subsequent illustration, wherein the aluminum alloy
comprises: from 4.0 to
15.0 wt. A) Zn; from 0.1 to 3.5 wt. % Cu; from 1.0 to 4.0 wt. % Mg; from 0.05
to 0.50 wt. %
Fe; from 0.05 to 0.30 wt. % Si; from 0.05 to 0.25 wt. % Zr; up to 0.25 wt. %
Mn; up to 0.20
wt. % Cr; up to 0.15 wt. % Ti; and up to 0.15 wt. % impurities; with the
remainder being Al.
[0159] Illustration 30 is the method of any preceding or subsequent
illustration, wherein
the aluminum alloy comprises: from 5.6 to 9.3 wt. % Zn; from 0.2 to 2.6 wt. %
Cu; from 1.4
to 2.8 wt. % Mg; from 0.10 to 0.35 wt. c/1/0 Fe; from 0.05 to 0.20 wt. % Si;
from 0.05 to 0.15
wt. % Zr; up to 0.05 wt. % Mn; up to 0.10 wt. % Cr; up to 0.05 wt. % Ti; and
up to 0.15 wt.
% impurities; with the remainder being Al.
[0160] Illustration 31 is the method of any preceding or subsequent
illustration, further
comprising up to 0.10 wt. % of one or more elements selected from the group
consisting of
Mo, Nb, Be, B, Co, Sn, Sr, V, In, Hf, Ag, Sc, and Ni.
[0161] Illustration 32 is the method of any one of any preceding or
subsequent
illustration, further comprising up to 0.10 wt. % of one or more elements
selected from the
group consisting of Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb,
and Lu.
[0162] Illustration 33 is the method of any one of any preceding or
subsequent
illustration, wherein the casting is carried out by direct chill (DC) casting.
[0163] Illustration 34 is the method of any one of any preceding or
subsequent
illustration, wherein the casting is carried out by continuous casting.
[0164] Illustration 35 is the method of any preceding or subsequent
illustration, wherein
the casting is carried out by twin-belt continuous casting.
[0165] Illustration 36 is the method of any one of any preceding or
subsequent
illustration, wherein the one or more cold rolling passes of the rolling used
to form the first
rolled aluminum alloy product reduce the thickness of rolled aluminum product
by at least
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30%, or at least 35%, or at least 40%, or at least 45%, or at least 50%, or at
least 55%, or at
least 60%, or at least 65%, or at least 70%.
[0166] Illustration 37 is the method of any one of any preceding or
subsequent
illustration, wherein the first thickness is no more than 10 mm, or no more
than 9 mm, or no
more than 8 mm, or no more than 7 mm, or no more than 6 mm, or no more than 5
mm, or no
more than 4 mm.
[0167] Illustration 38 is the method of any one of any preceding or
subsequent
illustration, wherein the first thickness is from 1 mm to 10 mm, or from 2 mm
to 8 mm, or
from 3 mm to 6 mm.
[0168] Illustration 39 is the method of any one of any preceding or
subsequent
illustration, wherein the annealing of the first rolled aluminum alloy product
is carried out at
a temperature of no more than 45 C, or no more than 40 C, or no more than 35
C, or no
more than 30 C, or no more than 25 C, or no more than 20 C, or no more than
15 C, or no
more than 10 C, above the minimum recrystallization temperature of the
aluminum alloy.
[0169] Illustration 40 is the method of any one of any preceding or
subsequent
illustration, wherein the annealing of the first rolled aluminum alloy product
is carried out at
a temperature above the minimum recrystallization temperature of the aluminum
alloy for no
more than 3.0 hours, or no more than 2.5 hours, or no more than 2.0 hours, or
no more than
1.5 hours, or no more than 1.0 hours.
[0170] Illustration 41 is the method of any one of any preceding or
subsequent
illustration, wherein the second thickness is no more than 4.0 mm, or no more
than 3.5 mm,
or no more than 3.0 mm, or no more than 2.5 mm, or no more than 2.0 mm, or no
more than
1.5 mm, or no more than 1.0 mm, or no more than 0.5 mm, or no more than 0.3
mm, or no
more than 0.1 mm.
[0171] Illustration 42 is the method of any one of any preceding or
subsequent
illustration, further comprising treating the second rolled aluminum alloy
product to form a
finished aluminum alloy product.
[0172] Illustration 43 is the method of any preceding or subsequent
illustration, wherein
the treating comprises one or more processes selected from the group
consisting of:
annealing, solutionizing, quenching, ageing, and coiling
[0173] Illustration 44 is the method of any preceding or subsequent
illustration, wherein
the finished aluminum alloy product is an aluminum alloy sheet in the T6 or T7
temper.
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[0174] Illustration 45 is an aluminum alloy article, wherein the aluminum
alloy article is
the second rolled aluminum alloy product formed by the method of any one of
any preceding
or subsequent illustration.
[0175] Illustration 46 is an aluminum alloy article, wherein the aluminum
alloy article is
the finished aluminum alloy product formed by the method of any one of any
preceding or
subsequent illustration.
[0176] Illustration 47 is an article of manufacture, which is comprised of
an aluminum
alloy article of any one of any preceding or subsequent illustration.
[0177] Illustration 48 is the article of manufacture of any preceding or
subsequent
illustration, wherein the article of manufacture is an automobile, a truck, a
trailer, a train, a
railroad car, an airplane, a body panel or part for any of the foregoing, a
bridge, a pipeline, a
pipe, a tubing, a boat, a ship, a storage container, a storage tank, a an
article of furniture, a
window, a door, a railing, a functional or decorative architectural piece, a
pipe railing, an
electrical component, a conduit, a beverage container, a food container, or a
foil.
[0178] Illustration 49 is the article of manufacture of any preceding or
subsequent
illustration, wherein the article of manufacture is an automotive body part.
[0179] Illustration 50 is the article of manufacture of any preceding or
subsequent
illustration, wherein the automotive body part is a motor vehicle body part.
[0180] Illustration 51 is the article of manufacture of any preceding or
subsequent
illustration, wherein the motor vehicle body part is a bumper, a side beam, a
roof beam, a
cross beam, a pillar reinforcement, an inner panel, an outer panel, a side
panel, an inner hood,
an outer hood, or a trunk lid panel
[0181] Illustration 52 is the article of manufacture of any preceding or
subsequent
illustration, wherein the article of manufacture is an electronic device
housing.
[0182] Illustration 53 is the article of manufacture of any preceding or
subsequent
illustration, wherein the article of manufacture is an aerospace body part.
[0183] Illustration 54 is the article of manufacture of any preceding or
subsequent
illustration, wherein the aerospace body part is a structural body part.
[0184] Illustration 55 is the article of manufacture of any preceding or
subsequent
illustration, wherein the structural body part is a wing, a fuselage, an
aileron, a rudder, an
elevator, a cowling, or a support
[0185] Illustration 56 is the article of manufacture of any preceding or
subsequent
illustration, wherein the aerospace body part is a non-structural body part.
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[0186] Illustration 57 is the article of manufacture of any preceding or
subsequent
illustration, wherein the non-structural body part is a seat track, a seat
frame, a panel, or a
hinge.
[0187] Illustration 58 is a method of making an aluminum alloy article, the
method
comprising: casting an aluminum alloy to form an aluminum alloy cast product;
homogenizing the aluminum alloy cast product to form a homogenized aluminum
alloy cast
product; subjecting the homogenized aluminum alloy cast product to a first
rolling process to
form a first rolled aluminum alloy product having a first thickness, wherein
the first rolling
process comprises one or more hot rolling passes followed by one or more cold
rolling
passes; annealing the first rolled aluminum alloy product at a temperature of
not more than 50
C above a minimum recrystallization temperature of the aluminum alloy to form
a first
annealed aluminum product; and subjecting the first annealed aluminum alloy
product to a
second rolling process to form a second rolled aluminum alloy product having a
second
thickness.
[0188] Illustration 59 is the method of any preceding or subsequent
illustration, wherein
the aluminum alloy is a 5xxx series aluminum alloy, a 6xxx series aluminum
alloy, or a 7xxx
series aluminum alloy.
[0189] Illustration 60 is the method of any preceding or subsequent
illustration, wherein
the first thickness is no more than 10 mm.
[0190] Illustration 61 is the method of any preceding or subsequent
illustration, wherein
the annealing is carried out at the temperature above the minimum
recrystallization
temperature for no more than 3.0 hours.
[0191] Illustration 62 is the method of any preceding or subsequent
illustration, wherein
the annealing is carried out at a first temperature above the minimum
recrystallization
temperature for a first period of time and at a second temperature above the
minimum
recrystallization temperature for a second period of time, wherein the first
temperature above
the minimum recrystallization temperature is greater than the second
temperature above the
minimum recrystallization temperature.
[0192] Illustration 63 is the method of any preceding or subsequent
illustration, wherein
the second thickness is no more than 4.0 mm.
[0193] Illustration 64 is the method of any preceding or subsequent
illustration, wherein
the second rolled aluminum alloy product comprises: a first surface portion,
wherein the first
surface portion comprises a first rolled surface, and wherein the first
surface portion has a
first recrystallization quotient; a second surface portion opposing or
opposite the first surface
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portion, wherein the second surface portion comprises a second rolled surface,
and wherein
the second surface portion has a second recrystallization quotient; and an
intermediate portion
positioned between the first surface portion and the second surface portion,
wherein the
intermediate portion has a third recrystallization quotient, and wherein the
third
recrystallization quotient is less than the first recrystallization quotient
or the second
recrystallization quotient or both.
[0194] Illustration 65 is the method of any preceding or subsequent
illustration, wherein
the first recrystallization quotient is between 0.50 and 1.0, wherein the
second
recrystallization quotient is between 0.50 and 1.0, or wherein the third
recrystallization
quotient is between 0.01 and 0.65.
[0195] Illustration 66 is an aluminum alloy article comprising an aluminum
alloy
material, the aluminum alloy material comprising: a first surface portion,
wherein the first
surface portion comprises a first rolled surface, and wherein the first
surface portion has a
first recrystallization quotient; a second surface portion opposing or
opposite the first surface
portion, wherein the second surface portion comprises a second rolled surface,
and wherein
the second surface portion has a second recrystallization quotient; and an
intermediate portion
positioned between the first surface portion and the second surface portion,
wherein the
intermediate portion has a third recrystallization quotient, and wherein the
third
recrystallization quotient is less than the first recrystallization quotient
or the second
recrystallization quotient or both.
[0196] Illustration 67 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the aluminum alloy material is a 5xxx series aluminum
alloy, a 6xxx
series aluminum alloy, or a 7xxx series aluminum alloy.
[0197] Illustration 68 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein one or both of the first rolled surface or the second
rolled surface is
formed by a process that comprises cold rolling.
[0198] Illustration 69 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the first surface portion extends from a surface of the
first surface
portion to first a depth of no more than 40.0% of a thickness of the aluminum
alloy article.
[0199] Illustration 70 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the second surface portion extends from a surface of the
second surface
portion to a second depth of no more than 40.0% of the thickness of the
aluminum alloy
article.
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WO 2019/040356 PCT/US2018/047058
[0200] Illustration 71 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the intermediate portion extends from a first depth of
the first surface
portion to a second depth of the second surface portion.
[0201] Illustration 72 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the first surface portion has a first recrystallization
quotient, wherein the
second surface portion has a second recrystallization quotient, wherein the
intermediate
portion has a third recrystallization quotient, and wherein the third
recrystallization quotient
is less than the first recrystallization quotient or the second
recrystallization quotient or both.
[0202] Illustration 73 is the aluminum alloy article of any preceding or
subsequent
illustration, wherein the first recrystallization quotient is at least 0.50,
wherein the second
recrystallization quotient is at least 0.50, or wherein the third
recrystallization quotient is no
more than 0.65.
[0203] Illustration 74 is the aluminum alloy article of any preceding or
subsequent
illustration, having a 13 angle of between 1000 and 138 for bendability
testing according to
Specification VDA 238-100.
[0204] Illustration 75 is the aluminum alloy article of any preceding or
subsequent
illustration, having an exfoliation corrosion rating of EA for exfoliation
corrosion testing
according to ASTM Test No. G34-01.
[0205] Illustration 76 is the aluminum alloy article of any preceding
illustration, wherein
a recrystallization quotient corresponds to a percentage or fractional amount,
volume, or mass
of a portion of an aluminum alloy material, such as a surface portion or
intermediate portion,
that is recrystallized as compared to a total amount, volume, or mass of the
portion of the
aluminum alloy material.
[0206]
Various embodiments of the invention
have been described in fulfillment of the various objectives of the invention.
It should be
recognized that these embodiments are merely illustrative of the principles of
the present
invention. Numerous modifications and adaptations thereof will be readily
apparent to those
of ordinary skill in the art without departing from the spirit and scope of
the invention as
defined in the following claims.
43
Date Recue/Date Received 2021-08-18
