Note: Descriptions are shown in the official language in which they were submitted.
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LOW GAUGE, LEVELLED CAN BODY STOCK AND
METHODS OF MAKING THE SAME
PRIORITY
This application claims priority to and filing benefit of U.S. provisional
application
Serial No. 62/679,222 filed June 1, 2018, which is incorporated herein by
reference in its
entirety.
FIELD
The present disclosure is directed to aluminum alloy products and the
properties of
the same. The disclosure further relates to can body stock and methods of
producing and
processing the same.
BACKGROUND
Metal cans are well known and widely used as beverage containers. Conventional
beverage can bodies are generally made from metal at least 240 p.m in
thickness, which is
considered to be necessary to achieve the strength requirements for can
bodies. Beverage can
bodies are manufactured at high production rates and there is an ever-
increasing demand to
reduce metal content, and therefore cost, of the beverage can by down-gauging.
There are
also demands to further increase the production rate of beverage cans by
eliminating metal-
related jams at the cupper press and tear-offs and split domes at the
bodymakers. However,
the inherent non-flatness of cold-rolled aluminum sheets, insufficient surface
lubricity,
presence of surface fines and residual rolling oil, and formability properties
of existing
aluminum can body stock can prevent successful reduction in metal content
(light-weighting)
and can cause a reduction in productivity rates for can body production.
SUMMARY
Covered embodiments of the invention are defined by the claims, not this
summary.
This summary is a high-level overview of various aspects of the invention and
introduces
some of the concepts that are further described in the Detailed Description
section below.
This summary is not intended to identify key or essential features of the
claimed subject
matter, nor is it intended to be used in isolation to determine the scope of
the claimed subject
matter. The subject matter should be understood by reference to appropriate
portions of the
entire specification, any or all drawings, and each claim.
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Described herein is a method of producing an aluminum alloy product, such as
an
aluminum alloy sheet for use as can body stock. The method comprises casting
an aluminum
alloy comprising about 0.05 -0.4 wt. % Cu, 0.25 - 0.9 wt. % Fe, 0.8 - 3.0 wt.
% Mg, 0.1 -
2.0 wt. % Mn, 0.2 -0.7 wt. % Si, up to 0.1 wt. % Ti, up to 0.25 wt. % Zn, up
to 0.4 wt. % Cr,
up to 0.15 wt. % impurities, and Al, to form a cast aluminum alloy; heating
the cast
aluminum alloy; hot rolling the cast aluminum alloy to produce a rolled
product; cold rolling
the rolled product to produce an aluminum alloy product; and levelling the
aluminum alloy
product. Optionally, the casting can be performed by semi-continuous direct
chill ingot
casting or strip casting. In some cases, the step of heating the cast aluminum
comprises
homogenizing the cast aluminum alloy. The method can further comprise
degreasing the
aluminum alloy product, removing aluminum fines, rolling oil, and debris from
the aluminum
alloy product, and/or lubricating the aluminum alloy product with a cupping
lubricant. In
some cases, the degreasing process comprises use of a solvent or hot water.
Also described herein is an aluminum alloy product prepared according to the
method
described herein. The aluminum alloy can comprise a 3xxx series aluminum alloy
or a 5xxx
series aluminum alloy. In some cases, the aluminum alloy comprises about 0.05 -
0.3 wt. %
Cu, 0.4 - 0.8 wt. % Fe, 0.8 - 2.8 wt. % Mg, 0.1 - 1.5 wt. % Mn, 0.25 - 0.6 wt.
% Si, up to
0.1 wt. % Ti, 0.1 -0.25 wt. % Zn, up to 0.35 wt. % Cr, up to 0.15 wt. %
impurities, and Al.
The aluminum alloy product can be a sheet. In some cases, the aluminum alloy
product comprises a thickness of less than about 240 p.m (e.g., from about 170
p.m to less
than about 240 p.m or from about 180 p.m to about 230 p.m). The sheet can have
a
longitudinal yield strength of at least about 260 MPa (e.g., from about 260
NiPa to about 300
MPa). Optionally, one or more surfaces of the aluminum alloy product comprise
an isotropic
surface texture. The one or more surfaces of the aluminum alloy product can
optionally have
a texture aspect ratio of 0.1 to 0.7. In some cases, one or more surfaces of
the aluminum alloy
product comprise at least about 200 mg/m2 of cupping lubricant per side
(mg/m2/side) (e.g.,
from about 200 mg/m2/side to about 1000 mg/m2/side or from about 500
mg/m2/side to about
800 mg/m2/side). Optionally, one or more surfaces of the aluminum alloy
product comprise a
post-lubricant in an amount of from about 5 mg/m2/side to about 100 mg/m2/side
(e.g., from
about 10 mg/m2/side to about 25 mg/m2/side or from about 20 mg/m2/side to
about 50
mg/m2/side). In some cases, the post-lubricant can include dibutyl adipate,
dibutyl sebacate,
dihexyl adipate, dihexyl sebacate, dicyclohexyl adipate, dicyclohexyl
sebacate, dioctyl
adipate, dioctyl sebacate, diisodecyl adipate, diisodecyl sebacate, diundecyl
adipate,
diundecyl sebacate, didodecanyl adipate, didodecanyl sebacate, diphenyl
sebacate, diphenyl
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adipate, or mixtures of these. Optionally, the levelling of the aluminum alloy
product is
performed in a longitudinal direction. The levelling can be performed such
that residual
stresses from cold-rolling are reduced, which results in a much flatter
product. In some cases,
the aluminum alloy product is substantially free of aluminum fines, rolling
oil, and surface
debris from the rolling process. The aluminum alloy product can comprise a
beverage can
body.
Further described herein is an aluminum alloy product comprising an aluminum
alloy
comprising about 0.05 ¨0.4 wt. % Cu, 0.25 ¨0.9 wt. % Fe, 0.8 ¨3.0 wt. % Mg,
0.1 ¨2.0 wt.
% Mn, 0.2 ¨0.7 wt. % Si, up to 0.1 wt. % Ti, up to 0.25 wt. % Zn, up to 0.4
wt. % Cr, up to
0.15 wt. % impurities, and Al, wherein the aluminum alloy product comprises a
thickness of
less than about 240 p.m (e.g., from about 170 p.m to less than about 240 p.m
or from about
180 p.m to about 230 p.m). Optionally, the aluminum alloy comprises about 0.05
¨ 0.3 wt. %
Cu, 0.4 ¨ 0.8 wt. % Fe, 0.8 ¨ 2.8 wt. % Mg, 0.1 ¨ 1.5 wt. % Mn, 0.25 ¨ 0.6 wt.
% Si, up to
0.1 wt. % Ti, 0.1 ¨0.25 wt. % Zn, up to 0.35 wt. % Cr, up to 0.15 wt. %
impurities, and Al.
In some cases, one or more surfaces of the aluminum alloy product has a
texture aspect ratio
of 0.1 to 0.7.
Other objects and advantages of the invention will be apparent from the
following
detailed description of non-limiting examples.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a chart of yield strength with respect to soaking time for different
soaking
temperatures according to one example of the present disclosure.
FIG. 2 is a chart of ultimate tensile strength with respect to soaking time
for different
soaking temperatures according to one example of the present disclosure.
FIG. 3 is a chart of spread with respect to soaking time for different soaking
temperatures according to one example of the present disclosure.
FIG. 4 is a chart of total elongation with respect to soaking time for
different soaking
temperatures according to one example of the present disclosure.
FIG. 5 is a chart of yield stress with respect to soaking time for different
soaking
temperatures according to one example of the present disclosure.
DETAILED DESCRIPTION
Described herein are reduced gauge aluminum alloys with improved formability,
products including the aluminum alloys, and methods for making the products.
The
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aluminum alloy compositions and methods described herein provide an improved
aluminum
alloy sheet for the efficient production of products, such as aluminum
beverage can bodies, in
both raw material usage and production rate. For example, the aluminum alloy
sheets
described herein have a reduced gauge (e.g., from about 180 [tm to about 240
[tm) as
compared to conventional aluminum alloy sheets used for can bodies, and, in
turn, a reduced
amount of aluminum in each beverage can. The can bodies prepared from the
aluminum alloy
sheets described herein meet the desired strength properties for beverage cans
at this reduced
gauge.
Additionally, the aluminum alloy sheets described herein have an isotropic
surface
texture. The anisotropy of the surface can be measured by the Texture Aspect
Ratio (Str),
according to ISO 25178. The Str value is the ratio of the shortest wavelength
to the longest
wavelength measured in any direction relative to the rolling direction. In
some examples, the
Str value for the surface of alloy sheet as described herein is from about 0.1
to about 0.7. For
example, the Str value can be 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, or 0.7.
Conventional aluminum alloy
sheets used to prepare can body stock, however, typically have an anisotropic
surface texture.
The Str value for the surface of a conventional alloy sheet is less than 0.1.
The anisotropic
nature of conventional can body stock can cause formability issues, such as
split domes and
tear offs. The aluminum alloy products described herein are free of
significant anisotropy.
Further, the aluminum alloy sheets described herein can be used for the more
efficient
production of can bodies as compared to conventional can body stock prepared
according to
conventional methods. Conventional can body stock contains a high level of
surface debris
from hot rolling and cold rolling. Such debris causes a buildup of fines on
the cupper tooling
and additional tool-wear and also causes the need for frequent cleaning of the
bodymaker
coolant. According to some methods as described herein, the aluminum alloy
sheets for use
as the can body stock are degreased, levelled, and/or lubricated with a
suitable lubricant,
which enables a cupping press to efficiently operate at high speeds. For
example, a cupping
press can process the aluminum alloy sheets as described herein at speeds
ranging from 200
to 500 strokes per minute (spm) without significant feeding issues and without
need for the
application of an additional cupper lubricant.
Definitions and Descriptions:
The terms "invention," "the invention," "this invention," and "the present
invention"
used herein are intended to refer broadly to all of the subject matter of this
patent application
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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.
In this description, reference is made to alloys identified by aluminum
industry
designations, such as "series" or "3xxx." For an understanding of the number
designation
system most commonly used in naming and identifying aluminum and its alloys,
see
"International Alloy Designations and Chemical Composition Limits for Wrought
Aluminum
and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association
Alloy
Designations and Chemical Compositions Limits for Aluminum Alloys in the Form
of
Castings and Ingot," both published by The Aluminum Association.
As used herein, the meaning of "a," "an," or "the" includes singular and
plural
references unless the context clearly dictates otherwise.
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
mm, greater than about 20 mm, greater than about 25 mm, greater than about 30
mm,
15 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.
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.
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,
less than about 0.3 mm, or less than about 0.1 mm.
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.
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
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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.
The following aluminum alloys are described in terms of their elemental
composition
in weight percentage (wt. %) based on the total weight of the alloy. In
certain examples of
each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the
sum of the
impurities.
Aluminum Alloys and Products
Described herein are aluminum alloys, products prepared from the same, and
methods
of preparing the aluminum alloys and products. Products described herein
include, for
example, reduced gauge sheets having an isotropic surface texture. Such
products can be
used, for example, as can body stock. Specifically, the aluminum alloy
products described
herein, having a gauge of lower than about 240 p.m, exhibit the strength of
conventional
aluminum alloy can body stock having a 2401.tm gauge or greater. The aluminum
alloy
.. products described herein are advantageously levelled to produce a
relatively flat sheet,
which enables the efficient use of the aluminum alloy products in a cupping
press at high
speeds. The reduced gauge aluminum alloy sheets can display longitudinal yield
strengths of
260 NiPa and higher. In addition, the aluminum alloy products described herein
exhibit
exceptional surface qualities which result in a visually brighter aluminum
can. The aluminum
alloy products also exhibit excellent lubricity such that no additional
lubricant is needed prior
to cupping. Additionally, the aluminum fines, surface debris, and rolling oil
are removed
from the aluminum alloy product, reducing potential contamination to the
cupping and
bodymaker presses. As a result of the levelled and lubricated surfaces of the
products
disclosed herein, the downtime on cupping lines can be greatly reduced,
thereby resulting in a
significant improvement in production rates and decreased operating costs.
Furthermore, due to the isotropic rolled surface, the surface friction and
distribution of
the lubricant is no longer dependent on the rolling direction. A more
directionally uniform
topography therefore enhances the drawing, wall-ironing, and dome-forming
capabilities in
the bodymaker operation (e.g., fewer punch-throughs, tear-offs, split (or
"open") domes as
well as inhibiting the tendency to "bleedthrough").
Additionally, the aluminum alloy products as described herein can be advanced
on a
cupping line without the use of lubrication and feed rolls that may cause
surface damage or
stress deformation in the product. By utilizing the Lenz effect, the aluminum
alloy product
can be advanced on a cupping line by rotating a magnet to induce a current and
magnetic
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field. Use of the Lenz effect thereby eliminates the potential stress
deformations and/or
surface defects from traditional compression and pinch rolls.
Aluminum alloys for use in the products and methods described herein include
3xxx
series aluminum alloys and 5xxx series aluminum alloys. Suitable 3xxx series
aluminum
alloys include, for example, AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B,
AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A,
AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009,
AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016,
AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.
Suitable 5xxx series aluminum alloys include, for example, AA5005, AA5005A,
AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A,
AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119,
AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040,
AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449,
AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151,
AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A,
AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754,
AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556,
AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059,
AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283,
AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, and
AA5088.
In some examples, the alloys for use in the products and methods described
herein can
have the following elemental composition as provided in Table 1.
Table 1
Element Weight Percentage (wt. %)
Cu 0.05 - 0.4
Fe 0.25 - 0.9
Mg 0.8 - 3.0
Mn 0.1 - 2.0
Si 0.2 - 0.7
Ti 0 - 0.1
Zn 0 - 0.25
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Cr 0 - 0.4
Others 0 - 0.05 (each)
0 - 0.15 (total)
Al Remainder
In some examples, the alloy can have the following elemental composition as
provided in Table 2.
Table 2
Element Weight Percentage (wt. %)
Cu 0.05 - 0.3
Fe 0.4 - 0.8
Mg 0.8 - 2.8
Mn 0.1 - 1.5
Si 0.25 - 0.6
Ti 0 - 0.1
Zn 0.1 - 0.25
Cr 0 - 0.35
Others 0 - 0.05 (each)
0 - 0.15 (total)
Al Remainder
In some examples, the alloys described herein include copper (Cu) in an amount
of
from about 0.05 % to about 0.40 % (e.g., from about 0.05 % to about 0.35 % or
from about
0.10% to about 0.30%) based on the total weight of the alloy. For example, the
alloy can
include 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11 %, 0.12%, 0.13%, 0.14%,
0.15 %, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21 %, 0.22%, 0.23 %, 0.24%, 0.25
%,
0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31 %, 0.32%, 0.33 %, 0.34%, 0.35 %,
0.36%,
0.37 %, 0.38 %, 0.39 %, or 0.40 % Cu. All are expressed in wt. %.
In some examples, the alloys described herein include iron (Fe) in an amount
of from
about 0.25 % to about 0.9 % (e.g., from about 0.3 % to about 0.85 % or from
about 0.4 % to
about 0.8 %) based on the total weight of the alloy. For example, the alloy
can include 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
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%, 0.48 %, 0.49 %, 0.5 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57
%, 0.58 %,
0.59 %, 0.6 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %,
0.69 %, 0.7
%, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.8
%, 0.81 %,
0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, or 0.900 Fe.
All are
expressed in wt. %.
In some examples, the alloys described herein include magnesium (Mg) in an
amount
of from about 0.8 A to about 3.0 A (e.g., from about 0.8 A to about 2.8 %
or from about 1.0
A to about 2.5 %) based on the total weight of the alloy. For example , the
alloy can include
0.8 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %,
0.9 %, 0.91
%, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.0 %, 1.1
%, 1.2 %,
1.3 %, 1.4 %, 1.5 %, 1.6 %, 1.7 %, 1.8 %, 1.9 %, 2.0 %, 2.1 %, 2.2 %, 2.3 %,
2.4 %, 2.5 %,
2.6 %, 2.7 %, 2.8 %, 2.9 %, or 3.0 % Mg. All are expressed in wt. %.
In some examples, the alloys described herein include manganese (Mn) in an
amount
of from about 0.1 A to about 2.0 A (e.g., from about 0.1 A to about 1.5 %
or from about 0.5
.. A to about 1.5 %) based on the total weight of the alloy. For example, the
alloy can include
0.1 %, 0.11 %, 0.12 o, 0.13 %, 0.14 %, 0.15 %, 0.16 o, 0.17 %, 0.18 %, 0.19 o,
0.2 %, 0.21
%, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.2900 0.3 %, 0.31
%, 0.3200
033 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.4 %, 0.41 %, 0.42 %,
0.43 %,
0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.5 %, 0.51 %, 0.5200 0.53 %,
0.5400
0.55 %, 0.5600 0.57 %, 0.58 %, 0.59 %, 0.600 0.61 %, 0.62 %, 0.63 %, 0.6400
0.65 %,
0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.7 %, 0.71 %, 0.72 %, 0.73 %, 0.7400 0.75 %,
0.7600
0.77 %, 0.78 %, 0.79 %, 0.8 %, 0.81 %, 0.82 %, 0.83 %, 0.8400 0.85 %, 0.8600
0.8700
0.88 %, 0.89 %, 0.9 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.9600 0.9700
0.98 %,
0.99 %, 1.0 %, 1.1 %, 1.2 %, 1.3 %, 1.4 %, 1.500 1.6 %, 1.7 %, 1.8 %, 1.9 %,
or 2.0 %Mn.
All are expressed in wt. %.
In some examples, the alloys described herein include silicon (Si) in an
amount of
from about 0.2 A to about 0.7 A (e.g., from about 0.25 A to about 0.6 % or
from about 0.3 A
to about 0.55 %) based on the total weight of the alloy. For example, the
alloy can include 0.2
%, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3
%, 0.31 %,
0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.4 %, 0.41 %,
0.42 %,
0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.5 %, 0.51 %, 0.52 %,
0.53 %,
0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.6 %, 0.61 %, 0.62 %, 0.63 %,
0.64 %,
0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, or 0.7 A Si. All are expressed in wt.
%.
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In some examples, the alloys described herein include titanium (Ti) in an
amount up
to about 0.1 % (e.g., from about 0.01 % to about 0.08 % or from about 0.02 %
to about 0.05
%) based on the total weight of the alloy. For example, the alloy can include
0.01 %, 0.02 %,
0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, or 0.1 % Ti. In some
cases, Ti is
not present in the alloy (i.e., 0 %). All are expressed in wt. %.
In some examples, the alloys described herein include zinc (Zn) in an amount
up to
about 0.25 % (e.g., from about 0.01 % to about 0.25 % or from about 0.1 % to
about 0.2 %)
based on the total weight of the alloy. For example, the alloy can include
0.01 %, 0.02 %,
0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1 %, 0.11 %, 0.12%, 0.13 %,
0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, or
0.25 % Zn. In some cases, Zn is not present in the alloy (i.e., 0 %). All are
expressed in wt.
%.
In some examples, the alloys described herein include chromium (Cr) in an
amount up
to about 0.4 % (e.g., from about 0.01 % to about 0.35 % or from about 0.05 %
to about 0.3
.. %) based on the total weight of the alloy. For example, the alloy can
include 0.01 %, 0.02 %,
0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1 %, 0.11 %, 0.12%, 0.13 %,
0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21 %, 0.22%, 0.23%, 0.24%,
0.25 %, 0.26%, 0.27%, 0.28%, 0.29%, 0.3 %, 0.31 %, 0.32%, 0.33 %, 0.34%, 0.35
%,
0.36 %, 0.37 %, 0.38 %, 0.39 %, or 0.4 % Cr. In some cases, Cr is not present
in the alloy
(i.e., 0 %). All are expressed in wt. %.
Optionally, the alloy compositions described herein can further include other
minor
elements, sometimes referred to as impurities, in amounts of 0.05 % or below,
0.04 % or
below, 0.03 % or below, 0.02 % or below, or 0.01 % or below. These impurities
may include,
but are not limited to Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof.
Accordingly, Zr,
Sn, Ga, Ca, Bi, Na, or Pb may be present in alloys in amounts of 0.05 % or
below, 0.04 % or
below, 0.03 % or below, 0.02 % or below or 0.01 % or below. In some cases, 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.
Various products including the aluminum alloys described herein can be
produced.
The aluminum alloy products described herein can have any suitable gauge. In
some
examples, the aluminum alloy product can be a sheet. Optionally, the sheet
gauge is less than
about 240 p.m (e.g., from about 170 p.m to less than about 240 p.m, from about
180 p.m to
about 230 p.m, or from about 190 p.m to about 220 m). For example, the sheet
can have a
gauge of about 170 p.m, 175 p.m, 180 p.m, 185 p.m, 190 p.m, 195 p.m, 200 p.m,
205 p.m, 210
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m, 215 m, 220 m, 225 m, 230 m, 235 m, or 240 m. The sheet can be used as
can
body stock.
Aluminum Alloy Product Properties
The aluminum alloy products as described herein have a combination of desired
properties, including suitable strength and high formability. The aluminum
alloy products can
exhibit a longitudinal yield strength of at least about 260 MPa (e.g., from
about 260 MPa to
about 300 MPa). For example, the longitudinal yield strength can be at least
about 260 MPa,
at least about 265 MPa, at least about 270 MPa, at least about 275 MPa, at
least about 280
MPa, at least about 285 MPa, at least 290 MPa, at least about 295 MPa, or at
least about 300
MPa.
In some examples, the aluminum alloy products are substantially uniform, with
few
areas of non-uniformity. Optionally, the aluminum alloy products can be
levelled, as
explained in further detail below, to reduce residual stress and cold-rolled
to generate an
isotropic surface texture. In some examples, an aluminum alloy product is
tension-levelled in
a longitudinal direction. In some examples, an aluminum alloy product is
thermally-levelled.
Optionally, the levelling of the aluminum alloy product, such as an aluminum
alloy strip, can
be measured on a flatness table with a resolution of 2 mm in the x- and y-
directions. The
flatness of the levelled sheet can be measured in I-units. In some cases, the
height and length
of the deviations (i.e., non-flat areas) can be measured and the I-unit can be
calculated by the
following formula:
I-unit = (DL/L) x 105 units (1)
wherein DL is deviation in length and L is the segment length of the levelled
sheet. In some
examples, the levelled sheet can have an I-value of about 50 or less (e.g.,
about 45 or less,
about 40 or less, about 35 or less, about 30 or less, about 25 or less, about
20 or less, about 15
or less, about 10 or less, or about 5 or less).
In some examples, one or more surfaces of the aluminum alloy products are
substantially free of rolling lubricant, aluminum fines, and debris. As used
herein, the term
"substantially free of rolling lubricant, aluminum fines, and debris" means
that the one or
more surfaces of the aluminum alloy products can include less than about 1%,
less than about
0.1%, less than about 0.01%, less than about 0.001%, less than about 0.0001%,
or 0% of the
component (e.g., rolling lubricant, aluminum fines, and/or debris) per square
millimeter
(mm2) of the aluminum alloy product surface. In some examples, the aluminum
alloy
products contain cupping lubricant on one or more surfaces for use in
downstream
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processing, such as in a cupping process. In some cases, one or more surfaces
of the
aluminum alloy products have at least about 200 mg of cupping lubricant per
square meter
(m2) per side (e.g., from about 200 mg/m2 to about 1000 mg/m2 or from about
500 mg/m2 to
about 800 mg/m2 cupping lubricant per side). For example, one or more surfaces
of the
aluminum alloy products can have about 200 mg/m2, about 250 mg/m2, about 300
mg/m2,
about 350 mg/m2, about 400 mg/m2, about 450 mg/m2, about 500 mg/m2, about 550
mg/m2,
about 600 mg/m2, about 650 mg/m2, about 700 mg/m2, about 750 mg/m2, about 800
mg/m2,
about 850 mg/m2, about 900 mg/m2, about 950 mg/m2, or about 1000 mg/m2 cupping
lubricant per side. The lubricant can eliminate the need for an additional
lubricant for
production of beverage can bodies.
In some cases, the aluminum alloy products contain post-lubricant on one or
more
surfaces to help inhibit corrosion related to moisture in the atmosphere and
fretting corrosion
due to interlap movement during transportation and unwinding. In some cases,
one or more
surfaces of the aluminum alloy products have at least about 5 mg of post-
lubricant per square
meter (m2) per side (e.g., from about 5 mg/m2 to about 100 mg/m2 or from about
25 mg/m2 to
about 75 mg/m2 post-lubricant per side). For example, one or more surfaces of
the aluminum
alloy products can have about 5 mg/m2, about 10 mg/m2, about 15 mg/m2, about
20 mg/m2,
about 25 mg/m2, about 30 mg/m2, about 35 mg/m2, about 40 mg/m2, about 45
mg/m2, about
50 mg/m2, about 55 mg/m2, about 60 mg/m2, about 65 mg/m2, about 70 mg/m2,
about 75
mg/m2, about 80 mg/m2, about 85 mg/m2, about 90 mg/m2, about 95 mg/m2, or
about 100
mg/m2 post-lubricant per side. In some cases, the post-lubricant can include
one or more of
dibutyl adipate, dibutyl sebacate, dihexyl adipate, dihexyl sebacate,
dicyclohexyl adipate,
dicyclohexyl sebacate, dioctyl adipate, dioctyl sebacate, diisodecyl adipate,
diisodecyl
sebacate, diundecyl adipate, diundecyl sebacate, didodecanyl adipate,
didodecanyl sebacate,
diphenyl sebacate, or diphenyl adipate.
Methods ofMaking
The aluminum alloys described above can be cast into a cast product. The
alloys can
be cast using any casting process performed according to standards commonly
used in the
aluminum industry as known to one of ordinary skill in the art. For example,
the alloys may
be cast using a continuous casting (CC) process that may include, but is not
limited to, the
use of twin belt casters, twin roll casters, or block casters. In some
examples, the casting
process is performed by a CC process to form a cast product such as a billet,
slab, shate, strip,
or the like. In some examples, the casting process is performed by a Direct
Chill (DC) casting
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process to form a cast product such as an ingot. In some examples, the casting
process is
performed by strip casting. The cast product can then be subjected to further
processing steps.
Such processing steps include, but are not limited to, a heating step, a hot
rolling step, a cold
rolling step, and/or an annealing step. Optionally, the heating step can
include homogenizing
the cast aluminum alloy. Optionally, the sheet can be further processed using
a degreasing
step, a levelling step, and/or a lubricating step.
Heating
The heating step can include heating a cast aluminum alloy product, such as an
ingot,
prepared from an aluminum alloy composition described herein to attain a peak
metal
temperature (PMT) of about, or at least about, 450 C (e.g., at least about
460 C, at least
about 470 C, at least about 480 C, at least about 490 C, at least about 500
C, at least about
510 C, at least about 520 C, at least about 530 C, at least about 540 C,
at least about 550
C, at least about 560 C, at least about 570 C, or at least about 580 C).
For example, the
cast aluminum alloy product can be heated to a temperature of from about 450
C to about
580 C, from about 460 C to about 575 C, from about 470 C to about 570 C,
from about
480 C to about 565 C, from about 490 C to about 555 C, or from about 500
C to about
550 C. In some cases, the heating rate to the PMT can be about 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,
C/hour or less, or 15 C/hour or less. In other cases, the heating rate to the
PMT can be
20 from about 10 C/min to about 100 C/min (e.g., from about 10 C/min to
about 90 C/min,
from about 10 C/min to about 70 C/min, from about 10 C/min to about 60
C/min, from
about 20 C/min to about 90 C/min, from about 30 C/min to about 80 C/min,
from about
40 C/min to about 70 C/min, or from about 50 C/min to about 60 C/min).
In some cases, the heating step includes homogenizing the cast aluminum alloy
where
the cast aluminum alloy product is allowed to soak (i.e., held at the
indicated temperature) for
a period of time. In some cases, the cast aluminum alloy product is allowed to
soak for at
least 30 minutes at a peak metal temperature as described above. According to
one non-
limiting example, the cast aluminum alloy product is allowed to soak for up to
about 36 hours
(e.g., from about 30 minutes to about 36 hours, inclusively). For example, the
cast aluminum
alloy product can be soaked at the peak metal temperature for 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, or anywhere in
between.
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Hot Rolling and Cold Rolling
Following the homogenization step, a hot rolling step can be performed. The
hot
rolling
step can include a hot reversing mill operation and/or a hot tandem mill
operation. The hot
rolling step can be performed at a temperature ranging from about 250 C to
about 550 C
(e.g.,
from about 300 C to about 500 C or from about 350 C to about 450 C).
A cold rolling step can optionally be applied to form an aluminum alloy
product. For
example, the cast aluminum alloy product can be cold rolled to a thickness of
less than about
4 mm. In some examples, a sheet can have a thickness of less than 4 mm, less
than 3 mm, less
than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7
mm, less than
0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2
mm, or less than
0.1 mm. Optionally, the sheet gauge is less than about 240 p.m (e.g., from
about 170 p.m to
less than about 240 m, from about 180 p.m to about 230 m, or from about 190
p.m to about
220 m). For example, the sheet can have a gauge of about 170 m, 175 m, 180
m, 185
p.m, 190 p.m, 195 pm, 200 p.m, 205 p.m, 210 p.m, 215 p.m, 220 p.m, 225 pm, 230
p.m, 235
m, or 240 m. The sheet can be used as can body stock.
Degreasing
The process described herein can optionally include at least one degreasing
step
applied to the aluminum alloy product. The term "degreasing," as used herein,
includes
processing the aluminum alloy product to remove residual oil accumulated on
the surface
from the hot rolling and cold rolling processes. The degreasing step can also
remove residual
surface debris, rolling oil, and aluminum fines from the rolling processes.
The degreased
surface gives an improved surface appearance to the can body and reduces the
build-up of
fines during the cupping process. The degreasing agent for use in the
degreasing step can
include water and/or solvents. Optionally, the water for use in the degreasing
step can be hot
water (i.e., water having a temperature of at least about 35 C, such as from
about 35 C to
about 100 C). In some cases, the degreasing agents can include acidic or
alkaline agents. For
example, suitable acidic agents for use in the degreasing step include
phosphoric acid,
.. sulfuric acid, hydrochloric acid, or a mixture of these. In some cases, the
degreasing agent
can include a wetting agent. Optionally, the degreasing agent can be used in
combination
with electrochemical cleaning. In certain cases, the level of degreasing is
controlled by the
concentration of the agents, current density, degreasing time, and/or
temperature in the
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degreasing section. After degreasing, the strip may be rinsed with water and
dried prior to
lubrication.
Levelling
The process described herein can include at least one levelling step applied
to the
aluminum alloy product. The term "levelling," as used herein, includes
processing the
aluminum alloy product to remove residual rolling stresses, thus generating an
aluminum
alloy product that is tension-levelled. The levelling step can also eliminate
uneven areas
resulting from the residual stresses from the rolling processes. By
eliminating uneven areas of
the aluminum alloy product, the cupping presses can run at increased operating
speeds and
throughput, thus resulting in higher productivity. The isotropic surface
texture of the
aluminum alloy product reduces cracked domes and reduces tear-offs and bleed-
through and
looper lines during the cupping and bodymaker processes. Any suitable
levelling process can
be used, including tension-levelling, stretch-levelling, roller-levelling,
and/or thermal-
levelling. Not wishing to be bound by theory, mechanical levelling such as
tension-, stretch-,
and roller-levelling processes can extend certain ligaments in the strip, and
thermal-levelling
processes can allow dislocations within the strip to relax and deform to
eliminate stress
differences within the strip, thereby ensuring lower residual stresses in the
sheet and an
improved strip shape, i.e. flatness. In addition, the level of distortion in
the remaining
portions of the sheet, e.g., after blanking the cups on the cupping press, is
greatly reduced.
In some examples, the strip may be heated to a peak metal temperature of about
170
C to about 280 C (e.g., from about 200 C to about 240 C) for a period of
about 5 seconds
to about 15 seconds to thermally-level the strip. For example, the peak metal
temperature for
thermally-levelling the strip can be about 170 C, 171 C, 172 C, 173 C, 174
C, 175 C, 176
C, 177 C, 178 C, 179 C, 180 C, 181 C, 182 C, 183 C, 184 C, 185 C, 186
C, 187 C,
188 C, 189 C, 190 C, 191 C, 192 C, 193 C, 194 C, 195 C, 196 C, 197
C, 198 C, 199
C, 200 C, 201 C, 202 C, 203 C, 204 C, 205 C, 206 C, 207 C, 208 C, 209
C, 210 C,
211 C, 212 C, 213 C, 214 C, 215 C, 216 C, 217 C, 218 C, 219 C, 220
C, 221 C, 222
C, 223 C, 224 C, 225 C, 226 C, 227 C, 228 C, 229 C, 230 C, 231 C, 232
C, 233 C,
234 C, 235 C, 236 C, 237 C, 238 C, 239 C, 240 C, 241 C, 242 C, 243
C, 244 C, 245
C, 246 C, 247 C, 248 C, 249 C, 250 C, 251 C, 252 C, 253 C, 254 C, 255
C, 256 C,
257 C, 258 C, 259 C, 260 C, 261 C, 262 C, 263 C, 264 C, 265 C, 266
C, 267 C, 268
C, 269 C, 270 C, 271 C, 272 C, 273 C, 274 C, 275 C, 276 C, 277 C, 278
C, 279 C,
or 280 C. The thermally-levelling process time can be, for example, about 5
seconds, 6
seconds, 7 seconds, 8 seconds, 9 seconds, 10 seconds, 11 seconds, 12 seconds,
13 seconds, 14
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seconds, or 15 seconds. The strip may be cooled to ambient temperature after
the levelling
process. The line speed can be adjusted to impact the levelling process. In
some examples,
the line speed may about 100 m/min to about 300 m/min (e.g., from about 150
m/min to
about 200 m/min). For example, the line speed for levelling can be about 100
m/min, 105
m/min, 110 m/min, 115 m/min, 120 m/min, 125 m/min, 130 m/min, 135 m/min, 140
m/min,
145 m/min, 150 m/min, 155 m/min, 160 m/min, 165 m/min, 170 m/min, 175 m/min,
180
m/min, 185 m/min, 190 m/min, 195 m/min, 200 m/min, 205 m/min, 210 m/min, 215
m/min,
220 m/min, 225 m/min, 230 m/min, 235 m/min, 240 m/min, 245 m/min, 250 m/min,
255
m/min, 260 m/min, 265 m/min, 270 m/min, 275 m/min, 280 m/min, 285 m/min, 290
m/min,
295 m/min, or 300 m/min. In some examples, the levelled product is
substantially free of
residual rolling stresses. As used herein, the term "substantially free of
residual rolling
stresses" means that the aluminum alloy products can have an I-value of about
50 or less
(e.g., about 45 or less, about 40 or less, about 35 or less, about 30 or less,
about 25 or less,
about 20 or less, about 15 or less, about 10 or less, or about 5 or less). The
low level of
residual rolling stresses facilitates press feeding and remaining material
(web) ejection
processes.
Lubricating
The process described herein can optionally include at least one lubricating
step
applied to the aluminum alloy product. The term "lubricating," as used herein,
includes
processing the aluminum alloy product to apply a lubricant for subsequent
cupping
production. Optionally, the lubricant applied can be a dry film lubricant. In
some cases, the
lubricant can be applied uniformly. In some cases, a preferred level of
lubrication is within
the range of 200 to 1000 mg/m2/side of the product (e.g., from about 200
mg/m2/side to about
1000 mg/m2/side or from about 500 mg/m2/side to about 800 mg/m2/side). In some
cases, the
lubricating step eliminates the need for the use of additional lubricant
during downstream
processing (e.g., during the cupping process). In some cases, a post-lubricant
may be applied
to one or both surfaces to help inhibit corrosion related to moisture in the
atmosphere and
fretting corrosion due to interlap movement (e.g., caused by the overlapping
layers of the
aluminum alloy product as coiled) during transportation and unwinding. The
post-lubricant
may be applied to one or both surfaces in an amount of from about 5 mg/m2/side
to about 100
mg/m2/side (e.g., from about 10 mg/m2/side to about 25 mg/m2/side or from
about 20
mg/m2/side to about 50 mg/m2/side). In some cases, the post-lubricant can
include one or
more of dibutyl adipate, dibutyl sebacate, dihexyl adipate, dihexyl sebacate,
dicyclohexyl
adipate, dicyclohexyl sebacate, dioctyl adipate, dioctyl sebacate, diisodecyl
adipate,
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diisodecyl sebacate, diundecyl adipate, diundecyl sebacate, didodecanyl
adipate, didodecanyl
sebacate, diphenyl sebacate, or diphenyl adipate.
Methods of Using and Downstream Processing
The aluminum alloy products and methods described herein can be used for
preparing
beverage cans, food containers, or any other desired application. In some
examples, the
aluminum alloy products and methods can be used to prepare beverage can
bodies. The
aluminum alloy products as described herein can be used in downstream
processing, such as
in a cupping process. The aluminum alloy products as described above can be
moved in a
cupping process without using pinch rollers. In particular, rotating a magnet
adjacent to the
aluminum product produces an induced current and magnetic field, causing the
aluminum
product to move along the generated magnetic field. The induced current and
magnetic field
can be particularly useful in a rapid production line, such as in a beverage
can production
line. In some cases, the magnet can be placed in front of a cupping machine,
and the magnet
can be pulsed to move the aluminum alloy product forward. This method of
moving the
aluminum alloy product is referred to as the Lenz effect. By utilizing the
Lenz effect, the
aluminum alloy product (e.g., sheet or can preforms prepared from a sheet) can
be advanced
along the production line without the use of pinch rollers that compress the
product and can
potentially scratch the product surface or cause surface deformations that are
undesirable in a
finished beverage can.
EXAMPLES
Example
Sheets of 3104-01 aluminum were tested for yield strength, ultimate tensile
strength,
spread, and total elongation. Sheets were then partially annealed at peak
metal temperatures
of 180 C, 200 C and 220 C for soaking times of 5, 10, and 15 seconds. The
sheets were
tested for yield strength, ultimate tensile strength, spread, and total
elongation after the soak
time was complete. FIG. 1 shows the change in yield strength according to soak
time and
soak temperature. FIG. 2 shows the change in ultimate tensile strength
according to soak
time and soak temperature. For both, the sheets treated at 220 C reacted
faster than those at
lower temperatures. A decrease in strength was observed in 5 seconds at 220
C, whereas the
sheets treated at 180 C, 200 C showed little change in strength at 5
seconds. FIG. 3 shows
the change in spread according to soak time and soak temperature. Spread is
the numerical
difference between the yield strength and the ultimate tensile strength.
Again, the sheets
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treated at 220 C reacted faster than those at lower temperatures, but overall
the spread
remained steady. FIG. 4 shows the change in elongation according to soak time
and soak
temperature. Again, the sheets treated at 220 C reacted faster than those at
lower
temperatures, but did not show further reduction at 10 seconds or 15 seconds
of soak time.
The lower temperatures were slower to react, but showed a decrease in
elongation with
increased soak time.
Example 2
Sheets of 3104 were partially annealed at peak metal temperatures of 180 C,
200 C
and 220 C for soaking times of 5, 10, and 15 minutes. The sheets were then
cooled in a
furnace from 170 C to 100 C followed by an air quench and yield stress
measured. Three
replicates were tested at each temperature for a total of 27 samples. A
process model was
used to predict yield stress for 3104 sheets partially annealed at peak metal
temperatures
ranging from 100 C to 240 C for soaking time of 1 second to 1,000,000
minutes. FIG. 5
shows the experimental stress results represented with markers overlaid on the
lines of the
process model. The yield stress deceased over time, with greatest decrease
seen at higher
temperatures. The modeled results correlate well the experimental results at
temperatures up
to 200 C. At temperatures beyond 200 C, the experimental decrease in yield
stress is
greater than that predicted by the model.
Illustrations of Suitable Alloys, Products, and Methods
As used below, any reference to a series of illustrative alloys, products, or
methods is
to be understood as a reference to each of those alloys, products, or methods
disjunctively
(e.g., "Illustrations 1-4" is to be understood as "Illustration 1, 2, 3, or
4").
Illustration 1 is a method of producing an aluminum alloy product, comprising
casting
an aluminum alloy comprising about 0.05 ¨ 0.4 wt. % Cu, 0.25 ¨ 0.9 wt. % Fe,
0.8 ¨ 3.0 wt.
% Mg, 0.1 ¨2.0 wt. % Mn, 0.2 ¨0.7 wt. % Si, up to 0.1 wt. % Ti, up to 0.25 wt.
% Zn, up to
0.4 wt. % Cr, up to 0.15 wt. % impurities, and Al, to form a cast aluminum
alloy, heating the
cast aluminum alloy, hot rolling the cast aluminum alloy to produce a rolled
product, cold
.. rolling the rolled product to produce an aluminum alloy product, and
levelling the aluminum
alloy product.
Illustration 2 is the method of any preceding or subsequent illustration,
wherein
casting is performed by semi-continuous direct chill ingot casting or strip
casting.
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Illustration 3 is the method of any preceding or subsequent illustration,
wherein
heating the cast aluminum alloy comprises homogenizing the cast aluminum alloy
Illustration 4 is the method of any preceding or subsequent illustration,
further
comprising degreasing the aluminum alloy product.
Illustration 5 is the method of any preceding or subsequent illustration,
further
comprising removing aluminum fines, rolling oil, and debris from the aluminum
alloy
product.
Illustration 6 is the method of any preceding or subsequent illustration,
further
comprising lubricating the aluminum alloy product with a cupping lubricant.
Illustration 7 is an aluminum alloy product prepared according to the method
of any
preceding or subsequent illustration.
Illustration 8 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy comprises a 3xxx series aluminum
alloy.
Illustration 9 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy comprises a 5xxx series aluminum
alloy.
Illustration 10 is the aluminum alloy product of any preceding or subsequent
illustration, comprising about 0.05 ¨ 0.3 wt. % Cu, 0.4 ¨ 0.8 wt. % Fe, 0.8 ¨
2.8 wt. % Mg,
0.1 ¨ 1.5 wt. % Mn, 0.25 ¨ 0.6 wt. % Si, up to 0.1 wt. % Ti, 0.1 ¨0.25 wt. %
Zn, up to 0.35
wt. % Cr, up to 0.15 wt. % impurities, and Al.
Illustration 11 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy product is a sheet.
Illustration 12 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy product comprises a thickness of less
than about 240
[tm.
Illustration 13 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the thickness is from about 170 p.m to less than about
240 p.m.
Illustration 14 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the thickness is from about 180 p.m to about 230 p.m.
Illustration 15 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the sheet has a longitudinal yield strength of at least
about 260 MPa.
Illustration 16 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the longitudinal yield strength is from about 260 MPa to
about 300 MPa.
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PCT/US2019/034906
Illustration 17 is the aluminum alloy product of any preceding or subsequent
illustration, wherein one or more surfaces of the aluminum alloy product
comprise an
isotropic surface topography.
Illustration 18 is the aluminum alloy product of any preceding or subsequent
illustration, wherein one or more surfaces of the aluminum alloy product has a
texture aspect
ratio of 0.1 to 0.7.
Illustration 19 is the aluminum alloy product of any preceding or subsequent
illustration, wherein one or more surfaces of the aluminum alloy product
comprise at least
about 200 mg of cupping lubricant per square meter per side (mg/m2/side).
Illustration 20 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the one or more surfaces of the aluminum alloy product
comprise
cupping lubricant in an amount of from about 200 mg/m2/side to about 1000
mg/m2/side.
Illustration 21 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the one or more surfaces of the aluminum alloy product
comprise a post-
lubricant in an amount of from about 5 mg/m2/side to about 100 mg/m2/side.
Illustration 22 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the post-lubricant comprises dibutyl adipate, dibutyl
sebacate, dihexyl
adipate, dihexyl sebacate, dicyclohexyl adipate, dicyclohexyl sebacate,
dioctyl adipate,
dioctyl sebacate, diisodecyl adipate, diisodecyl sebacate, diundecyl adipate,
diundecyl
sebacate, didodecanyl adipate, didodecanyl sebacate, diphenyl sebacate or
diphenyl adipate.
Illustration 23 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the sheet is tension-levelled in a longitudinal
direction.
Illustration 24 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the sheet is thermally-levelled at a temperature ranging
from about 170
C to about 280 C.
Illustration 25 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy product is substantially free of
aluminum fines and
debris.
Illustration 26 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy product comprises a beverage can
body.
Illustration 27 is an aluminum alloy product, comprising an aluminum alloy
comprising about 0.05 ¨0.4 wt. % Cu, 0.25 ¨0.9 wt. % Fe, 0.8 ¨3.0 wt. % Mg,
0.1 ¨2.0 wt.
% Mn, 0.2 ¨0.7 wt. % Si, up to 0.1 wt. % Ti, up to 0.25 wt. % Zn, up to 0.4
wt. % Cr, up to
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CA 03101809 2020-11-26
WO 2019/232374
PCT/US2019/034906
0.15 wt. % impurities, and Al, wherein the aluminum alloy product comprises a
thickness of
less than about 240 p.m.
Illustration 28 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the thickness is from about 170 p.m to less than about
240 p.m.
Illustration 29 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the thickness is from about 180 p.m to about 230 p.m.
Illustration 30 is the aluminum alloy product of any preceding or subsequent
illustration, wherein the aluminum alloy comprises about 0.05 ¨ 0.3 wt. % Cu,
0.4 ¨ 0.8 wt.
% Fe, 0.8 ¨ 2.8 wt. % Mg, 0.1 ¨ 1.5 wt. % Mn, 0.25 ¨ 0.6 wt. % Si, up to 0.1
wt. % Ti, 0.1 ¨
0.25 wt. % Zn, up to 0.35 wt. % Cr, up to 0.15 wt. % impurities, and Al.
Illustration 31 is the aluminum alloy product of any preceding or subsequent
illustration, wherein one or more surfaces of the aluminum alloy product has a
texture aspect
ratio of 0.1 to 0.7.
All patents, publications, and abstracts cited above are incorporated herein
by
reference in their entireties. Various embodiments of the invention have been
described in
fulfillment of the various objectives of the invention. It should be
recognized that these
embodiments are merely illustrative of the principles of the present
invention. Numerous
modifications and adaptions thereof will be readily apparent to those skilled
in the art without
departing from the spirit and scope of the present invention as defined in the
following
claims.
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