TECHNIQUES FOR PRODUCING ALUMINUM ALLOY PRODUCTS HAVING IMPROVED FORMABILITY AND RECYCLABILITY

TECHNIQUES DE PRODUCTION DE PRODUITS EN ALLIAGE D'ALUMINIUM AYANT UNE FORMABILITE ET UNE APTITUDE AU RECYCLAGE AMELIOREES

English Abstract

Described are aluminum alloy products and methods of making aluminum alloy products in which the aluminum alloy products have carefully controlled intermetallic particle density and particle size. Such aluminum alloy products may exhibit favorable formability. Control over intermetallic particle size and density may allow for use of high amounts of recycled source content in aluminum alloy products.

French Abstract

La présente invention concerne des produits en alliage d'aluminium et des procédés de fabrication de produits en alliage d'aluminium dans lesquels les produits en alliage d'aluminium ont une densité de particules intermétalliques et une taille de particule soigneusement contrôlées. De tels produits en alliage d'aluminium peuvent présenter une formabilité favorable. La régulation de la taille et de la densité des particules intermétalliques peut permettre l'utilisation de quantités élevées de teneur en source recyclée dans des produits en alliage d'aluminium.

Claims

WHAT IS CLAIMED IS:
1. An aluminum alloy product comprising:
an aluminum alloy comprising aluminum, iron, magnesium, manganese, and
silicon, wherein a ratio of an iron wt. % in the aluminum alloy to a silicon
wt. % in the aluminum
alloy is from 0.5 to 5.0, and wherein the aluminum alloy includes a plurality
of particles
including a-phase intermetallic particles comprising aluminum, silicon, and
one or more of iron
or manganese and 0-phase intermetallic particles comprising aluminum and one
or more of iron
or manganese; and
wherein the aluminum alloy has a particle density for the plurality of
particles of
from 5 particles per i.tm2 to 30,000 particles per i.tm2 and wherein the
aluminum alloy has an
inter-particle spacing for the plurality of particles of from 1 p.m to 25 p.m.
2. The aluminum alloy product of claim 1, wherein the plurality of
particles
have diameters of from 500 nm to 50 p.m.
3. The aluminum alloy product of claim 1, wherein the particle density is
from 50 to 1,000 particles per i.tm2.
4. The aluminum alloy product of claim 1, wherein the aluminum alloy
comprises:
from 0.1 wt. % to 1.0 wt. % iron,
from 0.05 wt. % to 0.8 wt. % silicon,
from 0.2 wt. % to 2.0 wt. % manganese,
from 0.2 wt. % to 2.0 wt. % magnesium,
up to 0.5 wt. % copper,
up to 0.05 wt. % zinc, and
aluminum.
5. The aluminum alloy product of claim 1, wherein the aluminum alloy
comprises up to 0.15 wt. % impurities.
6. The aluminum alloy product of claim 1, wherein the aluminum alloy
comprises:

from 0.2 wt. % to 0.8 wt. % iron,
from 0.10 wt. % to 0.7 wt. % silicon,
from 0.6 wt. % to 1.0 wt. % manganese,
from 0.7 wt. % to 1.0 wt. % magnesium,
up to 0.25 wt. % copper,
up to 0.2 wt. % zinc,
up to 0.10 wt. % titanium,
up to 0.10 wt. % chromium,
up to 0.10 wt. % zirconium,
up to 0.10 wt. % vanadium, and
aluminum.
7. The aluminum alloy product of claim 1, wherein the aluminum alloy
comprises:
from 0.3 wt. % to 0.7 wt. % iron,
from 0.15 wt. % to 0.5 wt. % silicon,
from 0.8 wt. % to 1.2 wt. % manganese,
from 0.9 wt. % to 1.2 wt. % magnesium,
from 0.1 wt. % to 0.2 wt. % copper,
up to 0.15 wt. % zinc,
up to 0.08 wt. % titanium,
up to 0.05 wt. % chromium,
up to 0.05 wt. % zirconium,
up to 0.05 wt. % vanadium, and
aluminum.
8. The aluminum alloy product of claim 1, wherein the a-phase intermetallic
particles comprise from 0.5% to 4.0% by volume of the aluminum alloy, and
wherein the 0-
phase intermetallic particles comprise from 0% to 2.0% by volume of the
aluminum alloy.
9. The aluminum alloy product of claim 1, wherein a ratio of an a-phase
intermetallic particle number density to a 0-phase intermetallic particle
number density is from
96

0.2 to 1,000 or wherein a ratio of a volume % of the a-phase intermetallic
particles to a volume
% of the 0-phase intermetallic particles is from 0.6 to 1,000.
10. The aluminum alloy product of claim 9, wherein the ratio of the a-phase
intermetallic particle number density to the 0-phase intermetallic particle
number density is from
0.3 to 3.
11. The aluminum alloy product of claim 1, wherein 80 percent or more of
the
plurality of particles have an inter-particle spacing from 5 p.m to 15 p.m.
12. The aluminum alloy product of claim 1, wherein the plurality of
particles
comprise iron-containing particles, wherein a majority of the iron-containing
particles have a
diameter from 1 p.m to 40 p.m.
13. The aluminum alloy product of claim 12, wherein the iron-containing
particles comprise from 1% to 4% of a total volume of the aluminum alloy.
14. The aluminum alloy product of claim 1, further comprising manganese-
containing dispersoids, wherein a majority of the manganese-containing
dispersoids have a
diameter of from 10 nm to 1.5 p.m.
15. The aluminum alloy product of claim 14, wherein the manganese-
containing dispersoids comprise up to 1% of a total volume of the aluminum
alloy.
16. The aluminum alloy product of claim 1, wherein the aluminum alloy
comprises a homogenized 3xxx series aluminum alloy, wherein the ratio of the
iron wt. % in the
homogenized 3xxx series aluminum alloy to the silicon wt. % in the homogenized
3xxx series
aluminum alloy is from 0.5 to 1.0, and wherein the homogenized 3xxx series
aluminum alloy
includes a-phase intermetallic particles, and wherein at least a portion of
the a-phase
intermetallic particles are transformed from 0-phase intermetallic particles
during
homogenization of the homogenized 3xxx series aluminum alloy.
17. The aluminum alloy product of claim 16, wherein a ratio of an a-phase
intermetallic particle number density in the homogenized 3xxx series aluminum
alloy to a f3-
phase intermetallic particle number density in the homogenized 3xxx series
aluminum alloy is
97

from 2 to 1000 or wherein a ratio of a volume % of the a-phase intermetallic
particles to a
volume % of the .beta.-phase intermetallic particle is from 0.6 to 1000.
18. The aluminum alloy product of claim 16, wherein the homogenized 3xxx
series aluminum alloy is subjected to one or more rolling processes.
19. The aluminum alloy product of claim 16, wherein the homogenized 3xxx
series aluminum alloy comprises:
from 0.8-1.4 wt. % magnesium;
from 0.8-1.3 wt. % manganese;
up to 0.25 wt. % copper;
from 0.25-0.7 wt. % silicon;
up to 0.7 wt. % iron;
up to 0.25 wt. % zinc; and
aluminum.
20. A method of making an aluminum alloy product, the method comprising:
preparing a cast aluminum alloy product comprising an aluminum alloy, wherein
the aluminum alloy comprises aluminum, iron, magnesium, manganese, and
silicon, wherein a
ratio of a silicon wt. % in the aluminum alloy to an iron wt. % in the
aluminum alloy is from 0.5
to 1.0, and wherein the aluminum alloy includes a plurality of particles
including a-phase
intermetallic particles comprising aluminum, silicon, and one or more of iron
or manganese and
.beta.-phase intermetallic particles comprising aluminum and one or more of
iron or manganese; and
homogenizing the cast aluminum alloy product to form a homogenized aluminum
alloy product by:
heating the cast aluminum alloy product to a homogenization temperature
from 500 °C to 650 °C; and
soaking the cast aluminum alloy product at the homogenization
temperature for a time duration from 0.1 hours to 36 hours, and
wherein the aluminum alloy product has a particle density for the plurality of
particles of from 5 to 30,000 particles per p.m' and wherein the aluminum
alloy product has an
inter-particle spacing for the plurality of particles of from 1 µm to 25
µm.
98

21. The method of claim 20, wherein the time duration is from 0.5 to 10
hours.
22. The method of claim 20, wherein the homogenization temperature is from
570 C to 620 C.
23. The method of claim 20, wherein the homogenization temperature is
within 25 C of a solidus temperature of the aluminum alloy.
24. The method of claim 20, wherein, during the soaking, a size of the 0-
phase
intermetallic particles decreases as compared to a size of the 0-phase
intermetallic particles prior
to the soaking.
25. The method of claim 20, wherein, during the soaking, a number density
of
the 0-phase intermetallic particles in the cast aluminum alloy product
decreases as compared to a
number density of the 0-phase intermetallic particles in the cast aluminum
alloy product prior to
the soaking.
26. The method of claim 20, wherein the plurality of particles comprises a
particle diameter from 500 nm to 50 i.tm.
27. The method of claim 20, wherein the particle density is from 50 to
1,000
particles per 1.tm2.
28. The method of claim 20, wherein the aluminum alloy comprises:
from 0.1 wt. % to 1.0 wt. % iron,
from 0.05 wt. % to 0.8 wt. % silicon,
from 0.2 wt. % to 2.0 wt. % manganese,
from 0.2 wt. % to 2.0 wt. % magnesium,
up to 0.5 wt. % copper,
up to 0.05 wt. % zinc, and
aluminum.
29. The method of claim 20, wherein the aluminum alloy comprises:
from 0.2 wt. % to 0.8 wt. % iron,
99

from 0.10 wt. % to 0.7 wt. % silicon,
from 0.6 wt. % to 1.0 wt. % manganese,
from 0.7 wt. % to 1.0 wt. % magnesium,
up to 0.25 wt. % copper,
up to 0.2 wt. % zinc,
up to 0.10 wt. % titanium,
up to 0.10 wt. % chromium,
up to 0.10 wt. % zirconium,
up to 0.10 wt. % vanadium, and
aluminum.
30. The method of claim 20, wherein the aluminum alloy comprises:
from 0.3 wt. % to 0.7 wt. % iron,
from 0.15 wt. % to 0.5 wt. % silicon,
from 0.8 wt. % to 1.2 wt. % manganese,
from 0.9 wt. % to 1.2 wt. % magnesium,
from 0.1 wt. % to 0.2 wt. % copper,
up to 0.15 wt. % zinc,
up to 0.08 wt. % titanium,
up to 0.05 wt. % chromium,
up to 0.05 wt. % zirconium,
up to 0.05 wt. % vanadium, and
aluminum.
31. The method of claim 20, wherein the a-phase intermetallic particles
comprise from 0.5% to 4.0% by volume of the aluminum alloy and the 0-phase
intermetallic
particles comprise from 0 to 2.0% by volume of the aluminum alloy.
32. The method of claim 20, wherein a ratio of an a-phase intermetallic
particle number density to a 0-phase intermetallic particle number density is
from 0.2 to 1,000 or
wherein a ratio of a volume % of the a-phase intermetallic particles to a
volume % of the 0-phase
intermetallic particles is from 0.6 to 1,000.
100

33. The method of claim 32, wherein the ratio of an a-phase intermetallic
particle number density to the 0-phase intermetallic particle number density
is from 0.3 to 3.
34. The method of claim 20, wherein 80 percent or more of the plurality of
particles have an inter-particle spacing from 5 p.m to 15 p.m.
35. The method of claim 20, wherein the plurality of particles comprise
iron-
containing particles, wherein a majority of the iron-containing particles have
an diameter from 1
p.m to 40 p.m.
36. The method of claim 35, wherein iron-containing particles comprise from
1% to 4% of a total volume of the aluminum alloy.
37. The method of claim 35, wherein the aluminum alloy further comprises
manganese-containing dispersoids, wherein the manganese-containing dispersoids
have a
diameter from 10 nm and 1.5 p.m.
38. The method of claim 37, wherein the manganese-containing dispersoids
comprise up to 1% of a total volume of the aluminum alloy.
39. The method of claim 20, wherein:
the cast aluminum alloy product comprises a 3xxx series aluminum alloy
including aluminum, iron, magnesium, manganese, and silicon, wherein a ratio
of a silicon wt. %
in the 3xxx series aluminum alloy to an iron wt. % in the 3xxx series aluminum
alloy is from 0.5
to 1.0, and wherein the cast aluminum alloy product includes 0-phase
intermetallic particles and
a-phase intermetallic particles;
the homogenization temperature is from 575 C to 615 C;
the time duration is from 12 hours to 36 hours; and
silicon from the 3xxx series aluminum alloy diffuses into and transforms at
least a
fraction of the 0-phase intermetallic particles into a-phase intermetallic
particles.
40. The method of claim 39, wherein the time duration is from 24 hours to
36
hours.
101

41. The method of claim 39, wherein the time duration is from 24 hours to
30
hours.
42. The method of claim 39, wherein the homogenization temperature is from
580 C to 610 C.
43. The method of claim 39, wherein the homogenization temperature is
within 25 C of a solidus temperature of the 3xxx series aluminum alloy.
44. The method of claim 39, wherein, during the soaking, iron diffuses out
of
the 0-phase intermetallic particles and is replaced by manganese.
45. The method of claim 39, wherein, during the soaking, iron diffuses out
of
the 0-phase intermetallic particles and combines with dispersoids present
within the cast
aluminum alloy product to form a-phase intermetallic particles.
46. The method of claim 45, wherein the dispersoids comprise manganese.
47. The method of claim 39, wherein, during the soaking, an average size of
the 0-phase intermetallic particles decreases as compared to an average size
of the 0-phase
intermetallic particles prior to soaking.
48. The method of claim 39, wherein, during the soaking, a number density
of
the 0-phase intermetallic particles in the cast aluminum alloy product
decreases as compared to a
number density of the 0-phase intermetallic particles in the cast aluminum
alloy product prior to
soaking.
49. The method of claim 39, wherein, during the soaking, 30% to 100% of the
0-phase intermetallic particles are transformed into a-phase intermetallic
particles.
50. The method of claim 39, wherein a ratio of an a-phase intermetallic
particle number density to a 0-phase intermetallic particle number density in
the homogenized
aluminum alloy product is from 2 to 1000.
102

51. The method of claim 39, wherein a ratio of an a-phase intermetallic
particle number density to a 0-phase intermetallic particle number density in
the cast aluminum
alloy product is from 0.3 to 3.
52. The method of claim 39, wherein the ratio of the silicon wt. % to the
iron
wt. % in the 3xxx series aluminum alloy is from 0.55 to 0.9.
53. The method of claim 39, wherein the 3xxx series aluminum alloy
comprises:
from 0.8-1.4 wt. % magnesium;
from 0.8-1.3 wt. % manganese;
up to 0.25 wt. % copper;
from 0.25-0.7 wt. % silicon;
up to 0.7 wt. % iron;
up to 0.25 wt. % zinc; and
aluminum.
54. The method of claim 39, wherein preparing the cast aluminum alloy
product comprises preparing a molten 3xxx series aluminum alloy and casting
the molten 3xxx
series aluminum alloy.
55. The method of claim 54, wherein preparing the molten 3xxx series
aluminum alloy comprises melting a combination of a 3xxx series source
aluminum alloy and a
5xxx series source aluminum alloy.
56. The method of claim 55, wherein the 3xxx series source aluminum alloy
and the 5xxx series source aluminum alloy are from a recycled source.
57. The method of claim 55, wherein preparing the molten 3xxx series
aluminum alloy further comprises melting a 4xxx series aluminum alloy or a
6xxx series
aluminum alloy with the 3xxx series source aluminum alloy and the 5xxx series
source
aluminum alloy.
103

58. The method of claim 39, wherein the homogenization temperature is a
first
homogenization temperature, and wherein the method further comprises:
reducing a temperature of the homogenized aluminum alloy product to a second
homogenization temperature less than the first homogenization temperature; and
soaking the homogenized aluminum alloy product at the second homogenization
temperature for a second time duration.
59. The method of claim 58, wherein the second time duration is from 1 hour
to 24 hours.
60. The method of claim 58, wherein the second homogenization temperature
is from 500 C to 600 C.
61. The method of claim 58, wherein soaking the homogenized aluminum
alloy product at the second homogenization temperature controls a surface
quality of the
homogenized aluminum alloy product.
62. The method of claim 39, further comprising subjecting the homogenized
aluminum alloy product to one or more rolling processes to produce a rolled
aluminum alloy
product.
63. A method for improving formability of a metal product, the method
comprising:
providing a cast metal product comprising a metal composite, wherein the metal
composite comprises iron, magnesium, manganese, and silicon, wherein a ratio
of a silicon wt. %
in the metal composite to an iron wt. % in the metal composite is from 0.5 to
1.0, and wherein
the metal composite includes a plurality of particles including a-phase
intermetallic particles
comprising silicon and one or more of iron or manganese and 0-phase
intermetallic particles
comprising one or more of iron or manganese; and
homogenizing the cast metal product to control an inter-particle spacing of
the
plurality of particles and to control a particle density of the plurality of
particles such to achieve
a ratio of an inter-particle spacing to particle density from 0.00034tm to
0.00064tm.
104

64. The method of claim 63, wherein the inter-particle spacing is from 1
i.tm
to 25 i.tm.
65. The method of claim 63, wherein the particle density is from 5 to
30,000
particles per i.tm2.
66. The method of claim 65, wherein the particle density is from 5 to 1,000
particles per i.tm2.
67. The method of claim 63, wherein the plurality of particles comprise a
particle diameter from 1 i.tm to 50 i.tm.
68. The method of claim 63, wherein homogenizing the cast metal product
comprises heating the cast metal product to a homogenization temperature from
400 C to 800
C and soaking the cast metal product at the homogenization temperature for a
time duration
from 0.1 hours to 48 hours.
69. The method of claim 68, wherein the homogenization temperature is
within 25 C of a solidus temperature of the cast metal product.
70. The method of claim 68, wherein homogenizing the cast metal product
further comprises subjecting the cast metal product to one or more of a hot
rolling process or a
cold rolling process.
105

Description

CA 03164133 2022-06-08
WO 2021/150610 PCT/US2021/014183
TECHNIQUES FOR PRODUCING ALUMINUM ALLOY PRODUCTS HAVING
IMPROVED FORMABILITY AND RECYCLABILITY
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Application No.
62/963,816, filed on January 21, 2020, which is hereby incorporated by
reference in its entirety.
FIELD
[0002] The present disclosure relates to metallurgy generally and more
specifically to
aluminum alloy products and techniques for improving formability of aluminum
alloy products,
particularly those containing high amounts of recycled source content. The
present disclosure
also relates to aluminum alloy products useful for beverage containers and
other aluminum alloy
products, and methods of preparing aluminum alloy products.
BACKGROUND
[0003] Formability is an important mechanical property of aluminum alloy
products. In
some instances, a reduction of constituent particle size within the aluminum
alloy microstructure
aims to improve formability. At the same time, environmental concerns call for
increased
recycled source content within aluminum alloy products. However, increasing
the recycled
source content of aluminum alloy products may reduce formability of the
aluminum alloy
products.
[0004] One industry that may benefit from increased formability and
increased recycled
source content is the beverage container industry. However, the composition of
aluminum alloys
used within the beverage containing industry may impact the formability and
recycled source
content of the beverage products. For example, AA3104 alloys which contain
manganese are
commonly used for beverage can body stock, while aluminum alloys containing
magnesium
(e.g., AA5182) have been used for beverage can end stock. Different aluminum
alloys may be
useful for meeting the needs of different beverage container technologies.
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SUMMARY
[0005] The term embodiment and like terms are intended to refer broadly to
all of the subject
matter of this disclosure and the claims below. Statements containing these
terms should be
understood not to limit the subject matter described herein or to limit the
meaning or scope of the
claims below. Embodiments of the present disclosure covered herein are defined
by the claims
below, not this summary. This summary is a high-level overview of various
aspects of the
disclosure and introduces some of the concepts that are further described in
the Detailed
Description section below. This summary is not intended to identify key or
essential features of
the claimed subject matter, nor is it intended to be used in isolation to
determine the scope of the
claimed subject matter. The subject matter should be understood by reference
to appropriate
portions of the entire specification of this disclosure, any or all drawings
and each claim.
[0006] Described herein are aluminum alloy products and methods of making
aluminum
alloy products in which the aluminum alloy products have been processed to
have a favorable
distribution of intermetallic particles, particle density, and/or spacing
between the particles
(inter-particle spacing), which may be beneficial for aluminum beverage
container making
processes and/or for minimizing and reducing galling and tear-offs during
drawing, ironing,
and/or necking during forming of an aluminum alloy product, (e.g., in the
process of making
aluminum beverage containers). Moreover, the ability to control particle
density and inter-
particle spacing to favorable values may allow for increased recycled source
content, benefiting
the environmental and economic cost of aluminum alloy product production.
Optionally, the
aluminum alloy includes a plurality of particles including a-phase
intermetallic particles
comprising aluminum, silicon, and one or more of iron or manganese.
Optionally, the aluminum
alloy includes a plurality of particles including 0-phase intermetallic
particles comprising
aluminum and one or more of iron or manganese. Optionally, the aluminum alloy
is from a
recycled source or is at least partially from a recycled source.
[0007] The aluminum alloys of some embodiments may exhibit ratios of iron
to silicon (e.g.,
ratios of wt. %) that may be greater than iron to silicon ratios in some
alloys conventionally used
in the beverage container making process. For example, ratios of iron wt. % to
silicon wt. % in
aluminum alloys described herein may range from about 0.5 to about 5.0, or may
be about 0.5,
0.6, 0.7, 0.8, 0.9, 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,
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2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2,
4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9,
and/or 5.0, for example. The disclosed aluminum alloys of some embodiments may
alternatively
exhibit ratios of silicon to iron (e.g., ratios of wt. %) that are greater
than silicon to iron ratios in
alloys conventionally used in the beverage container making process. For
example, ratios of
silicon wt. % to iron wt. % in aluminum alloys described herein may range from
about 0.5 to
about 1.0, such as from 0.5 to 1.0, such as from 0.5 to 0.6, from 0.5 to 0.7,
from 0.5 to 0.8, from
0.5 to 0.9, from 0.6 to 07, from 0.6 to 0.8, from 0.6 to 0.9, from 0.6 to 1.0,
from 0.7 to 0.8, from
0.7 to 0.9, from 0.7 to 1.0, from 0.8 to 0.9, from 0.8 to 1.0, or from 0.9 to
1.0, or about 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, 0.9, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98,
0.99, or 1, for example.
Increasing the amount of iron relative to the amount of silicon or the amount
of silicon relative to
the amount of iron in an aluminum alloy may be useful for controlling particle
sizes,
concentrations, distributions, particle density, inter-particle spacing,
and/or compositions of
intermetallic particles in the aluminum alloy. Additionally, using increased
amounts of iron in
an aluminum alloy may allow larger amounts of recycled source content to be
used.
[0008] Sizes, concentrations, density, inter-particle spacing, compositions
of particles, and/or
distribution of intermetallic particles in the aluminum alloy may
alternatively or additionally be
controlled by subjecting the aluminum alloy to suitable homogenization
conditions after casting.
For example, by homogenizing (soaking) the aluminum alloy at relatively long
durations (e.g.,
more than about 12 hours or more than about 24 hours), less favorable
intermetallic particles
may be transformed into more favorable particles. Such transformations may not
occur or not
occur to a significant enough extent during short duration (e.g., less than
about 24 hours or less
than about 12 hours) homogenization to suitably impact the size,
concentration, inter-particle
spacing, distribution of intermetallic particles, and/or composition of enough
numbers of
particles. For example, by subjecting an aluminum alloy to long, high
temperature
homogenization, less desirable intermetallic particles can have their chemical
and crystal
structures altered by diffusion of silicon into the particles and/or diffusion
of iron out of the
particles.
[0009] Optionally, an aluminum alloy product comprises an aluminum alloy
comprising
aluminum, iron, magnesium, manganese, and silicon. Optionally, a ratio of an
iron wt. % in the
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aluminum alloy to a silicon wt. % in the aluminum alloy is from 0.5 to 5.0,
such as from 0.5 to
1.0, from 0.5 to 1.1, from 0.5 to 1.5, from 0.5 to 1.8, from 0.5 to 2.0, from
0.5 to 2.5, from 0.5 to
3.0, from 0.5 to 3.5, from 0.5 to 4.0, from 0.5 to 4.5, from 1.0 to 1.1, from
1.0 to 1.5, from 1.0 to
1.8, from 1.0 to 2.0, from 1.0 to 2.5, from 1.0 to 3.0, from 1.0 to 3.5, from
1.0 to 4.0, from 1.0 to
4.5, from 1.0 to 5.0, from 1.1 to 1.5, from 1.1 to 1.8, from 1.1 to 2.0, from
1.1 to 2.5, from 1.1 to
3.0, from 1.1 to 3.5, from 1.1 to 4.0, from 1.1 to 4.5, from 1.1 to 5.0, from
1.5 to 1.8, from 1.5 to
2.0, from 1.5 to 2.5, from 1.5 to 3.0, from 1.5 to 3.5, from 1.5 to 4.0, from
1.5 to 4.5, from 1.5 to
5.0, from 1.8 to 2.0, from 1.8 to 2.5, from 1.8 to 3.0, from 1.8 to 3.5, from
1.8 to 4.0, from 1.8 to
4.5, from 1.8 to 5.0, from 2.0 to 2.5, from 2.0 to 3.0, from 2.0 to 3.5, from
2.0 to 4.0, from 2.0 to
4.5, from 2.0 to 5.0, from 2.5 to 3.0, from 2.5 to 3.5, from 2.5 to 4.0, from
2.5 to 4.5, from 2.5 to
5.0, from 3.0 to 3.5, from 3.0 to 4.0, from 3.0 to 4.5, from 3.0 to 5.0, from
3.5 to 4.0, from 3.5 to
4.5, from 3.5 to 5.0, from 4.0 to 4.5, from 4.0 to 5.0, or from 4.5 to 5Ø
Optionally, a ratio of a
silicon wt. % to an iron wt. % in an aluminum alloy products, such as
comprising a 3xxx series
aluminum alloy, may be from 0.5 to 1.0, such as from 0.5 to 0.55, from 0.5 to
0.6, from 0.5 to
0.65, from 0.5 to 0.7, from 0.5 to 0.75, from 0.5 to 0.8, from 0.5 to 0.85,
from 0.5 to 0.9, from
0.5 to 0.95, from 0.55 to 0.6, from 0.55 to 0.65, from 0.55 to 0.7, from 0.55
to 0.75, from 0.55 to
0.8, from 0.55 to 0.85, from 0.55 to 0.9, from 0.55 to 0.95, from 0.55 to 1.0,
from 0.6 to 0.65,
from 0.6 to 0.7, from 0.6 to 0.75, from 0.6 to 0.8, from 0.6 to 0.85, from 0.6
to 0.9, from 0.6 to
0.95, from 0.6 to 1, from 0.65 to 0.65, from 0.65 to 0.7, from 0.65 to 0.75,
from 0.65 to 0.8, from
0.65 to 0.85, from 0.65 to 0.9, from 0.65 to 0.95, from 0.65 to 1.0, from 0.7
to 0.75, from 0.7 to
0.8, from 0.7 to 0.85, from 0.7 to 0.95, from 0.7 to 1, from 0.75 to 0.8, from
0.75 to 0.85, from
0.75 to 0.9, from 0.75 to 0.95, from 0.75 to 1.0, from 0.8 to 0.85, from 0.8
to 0.9, from 0.8 to
0.95, from 0.8 to 1, from 0.85 to 0.9, from 0.85 to 0.95, from 0.85 to 1.0,
from 0.9 to 0.95, from
0.9 to 1, or from 0.95 to 1Ø An example 3xxx series aluminum alloy may
comprise from 0.8-
1.4 wt. % magnesium; from 0.8-1.3 wt. % manganese; up to 0.25 wt. % copper;
from 0.4-0.7 wt.
% silicon; up to 0.7 wt. % iron; up to 0.25 wt. % zinc; and aluminum.
[0010] In embodiments, the cast aluminum alloy product includes 0-phase
intermetallic
particles comprising aluminum and one or more of iron or manganese and/or a-
phase
intermetallic particles comprising aluminum, silicon, and one or more of iron
or manganese.
Optionally, a particle density, such as of 0-phase intermetallic particles
and/or a-phase
intermetallic particles, may be from 5 to 30,000 particles per i.tm2, such as
from 10 to 25,000,
4

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from 10 to 20,000, from 10 to 15,000, from 10 to 10,000, from 10 to 9,500,
from 10 to 9,000,
from 10 to 8,500, from 10 to 8,000, from 10 to 7,500, from 10 to 7,000, from
10 to 6,500, from
to 6,000, from 10 to 5,500, from 10 to 5,000, from 10 to 4,500, from 10 to
4,000, from 10 to
3,500, from 10 to 3,000, from 10 to 2,500, from 10 to 2,000, from 10 to 1,500,
from 10 to 1,000,
from 10 to 950, from 10 to 900, from 10 to 850, from 10 to 800, from 10 to
750, from 10 to 700,
from 10 to 650, from 10 to 600, from 10 to 550, from 10 to 500, from 10 to
450, from 10 to 400,
from 10 to 350, from 10 to 300, from 10 to 250, from 10 to 200, from 10 to
150, from 10 to 100,
from 10 to 75, from 10 to 50, from 10 to 25, from 25 to 30,000, from 25 to
25,000, from 25 to
20,000, from 25 to 15,000, from 25 to 10,000, from 25 to 9,500, from 25 to
9,000, from 25 to
8,500, from 25 to 8,000, from 25 to 7,500, from 25 to 7,000, from 25 to 6,500,
from 25 to 6,000,
from 25 to 5,500, from 25 to 5,000, from 25 to 4,500, from 25 to 4,000, from
25 to 3,500, from
25 to 3,000, from 25 to 2,500, from 25 to 2,000, from 25 to 1,500, from 25 to
1,000, from 25 to
950, from 25 to 900, from 25 to 850, from 25 to 800, from 25 to 750, from 25
to 700, from 25 to
650, from 25 to 600, from 25 to 550, from 25 to 500, from 25 to 450, from 25
to 400, from 25 to
350, from 25 to 300, from 25 to 250, from 25 to 200, from 25 to 150, from 25
to 100, from 25 to
75, from 25 to 50, from 50 to 30,000, from 50 to 25,000, from 50 to 20,000,
from 50 to 15,000,
from 50 to 10,000, from 50 to 9,500, from 50 to 9,000, from 50 to 8,500, from
50 to 8,000, from
50 to 7,500, from 50 to 7,000, from 50 to 6,500, from 50 to 6,000, from 50 to
5,500, from 50 to
5,000, from 50 to 4,500, from 50 to 4,000, from 50 to 3,500, from 50 to 3,000,
from 50 to 2,500,
from 50 to 2,000, from 50 to 1,500, from 50 to 1,000, from 50 to 950, from 50
to 900, from 50 to
850, from 50 to 800, from 50 to 750, from 50 to 700, from 50 to 650, from 50
to 600, from 50 to
550, from 50 to 500, from 50 to 450, from 50 to 400, from 50 to 350, from 50
to 300, from 50 to
250, from 50 to 200, from 50 to 150, from 50 to 100, from 50 to 75, from 75 to
30,000, from 75
to 25,000, from 75 to 20,000, from 75 to 15,000, from 75 to 10,000, from 75 to
9,500, from 75 to
9,000, from 75 to 8,500, from 75 to 8,000, from 75 to 7,500, from 75 to 7,000,
from 75 to 6,500,
from 75 to 6,000, from 75 to 5,500, from 75 to 5,000, from 75 to 4,500, from
75 to 4,000, from
75 to 3,500, from 75 to 3,000, from 75 to 2,500, from 75 to 2,000, from 75 to
1,500, from 75 to
1,000, from 75 to 950, from 75 to 900, from 75 to 850, from 75 to 800, from 75
to 750, from 75
to 700, from 75 to 650, from 75 to 600, from 75 to 550, from 75 to 500, from
75 to 450, from 75
to 400, from 75 to 350, from 75 to 300, from 75 to 250, from 75 to 200, from
75 to 150, from 75
to 100, from 100 to 30,000, from 100 to 25,000, from 100 to 20,000, from 100
to 15,000, from
5

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100 to 10,000, from 100 to 9,500, from 100 to 9,000, from 100 to 8,500, from
100 to 8,000, from
100 to 7,500, from 100 to 7,000, from 100 to 6,500, from 100 to 6,000, from
100 to 5,500, from
100 to 5,000, from 100 to 4,500, from 100 to 4,000, from 100 to 3,500, from
100 to 3,000, from
100 to 2,500, from 100 to 2,000, from 100 to 1,500, from 100 to 1,000, from
100 to 950, from
100 to 900, from 100 to 850, from 100 to 800, from 100 to 750, from 100 to
700, from 100 to
650, from 100 to 600, from 100 to 550, from 100 to 500, from 100 to 450, from
100 to 400, from
100 to 350, from 100 to 300, from 100 to 250, from 100 to 200, from 100 to
150, from 150 to
30,000, from 150 to 25,000, from 150 to 20,000, from 150 to 15,000, from 150
to 10,000, from
150 to 9,500, from 150 to 9,000, from 150 to 8,500, from 150 to 8,000, from
150 to 7,500, from
150 to 7,000, from 150 to 6,500, from 150 to 6,000, from 150 to 5,500, from
150 to 5,000, from
150 to 4,500, from 150 to 4,000, from 150 to 3,500, from 150 to 3,000, from
150 to 2,500, from
150 to 2,000, from 150 to 1,500, from 150 to 1,000, from 150 to 950, from 150
to 900, from 150
to 850, from 150 to 800, from 150 to 750, from 150 to 700, from 150 to 650,
from 150 to 600,
from 150 to 550, from 150 to 500, from 150 to 450, from 150 to 400, from 150
to 350, from 150
to 300, from 150 to 250, from 150 to 200, from 200 to 30,000, from 200 to
25,000, from 200 to
20,000, from 200 to 15,000, from 200 to 10,000, from 200 to 9,500, from 200 to
9,000, from 200
to 8,500, from 200 to 8,000, from 200 to 7,500, from 200 to 7,000, from 200 to
6,500, from 200
to 6,000, from 200 to 5,500, from 200 to 5,000, from 200 to 4,500, from 200 to
4,000, from 200
to 3,500, from 200 to 3,000, from 200 to 2,500, from 200 to 2,000, from 200 to
1,500, from 200
to 1,000, from 200 to 950, from 200 to 900, from 200 to 850, from 200 to 800,
from 200 to 750,
from 200 to 700, from 200 to 650, from 200 to 600, from 200 to 550, from 200
to 500, from 200
to 450, from 200 to 400, from 200 to 350, from 200 to 300, from 200 to 250,
from 250 to 30,000,
from 250 to 25,000, from 250 to 20,000, from 250 to 15,000, from 250 to
10,000, from 250 to
9,500, from 250 to 9,000, from 250 to 8,500, from 250 to 8,000, from 250 to
7,500, from 250 to
7,000, from 250 to 6,500, from 250 to 6,000, from 250 to 5,500, from 250 to
5,000, from 250 to
4,500, from 250 to 4,000, from 250 to 3,500, from 250 to 3,000, from 250 to
2,500, from 250 to
2,000, from 250 to 1,500, from 250 to 1,000, from 250 to 950, from 250 to 900,
from 250 to 850,
from 250 to 800, from 250 to 750, from 250 to 700, from 250 to 650, from 250
to 600, from 250
to 550, from 250 to 500, from 250 to 450, from 250 to 400, from 250 to 350,
from 250 to 300,
from 300 to 30,000, from 300 to 25,000, from 300 to 20,000, from 300 to
15,000, from 300 to
10,000, from 300 to 9,500, from 300 to 9,000, from 300 to 8,500, from 300 to
8,000, from 300 to
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CA 03164133 2022-06-08
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7,500, from 300 to 7,000, from 300 to 6,500, from 300 to 6,000, from 300 to
5,500, from 300 to
5,000, from 300 to 4,500, from 300 to 4,000, from 300 to 3,500, from 300 to
3,000, from 300 to
2,500, from 300 to 2,000, from 300 to 1,500, from 300 to 1,000, from 300 to
950, from 300 to
900, from 300 to 850, from 300 to 800, from 300 to 750, from 300 to 700, from
300 to 650, from
300 to 600, from 300 to 550, from 300 to 500, from 300 to 450, from 300 to
400, from 300 to
350, from 350 to 30,000, from 350 to 25,000, from 350 to 20,000, from 350 to
15,000, from 350
to 10,000, from 350 to 9,500, from 350 to 9,000, from 350 to 8,500, from 350
to 8,000, from 350
to 7,500, from 350 to 7,000, from 350 to 6,500, from 350 to 6,000, from 350 to
5,500, from 350
to 5,000, from 350 to 4,500, from 350 to 4,000, from 350 to 3,500, from 350 to
3,000, from 350
to 2,500, from 350 to 2,000, from 350 to 1,500, from 350 to 1,000, from 350 to
950, from 350 to
900, from 350 to 850, from 350 to 800, from 350 to 750, from 350 to 700, from
350 to 650, from
350 to 600, from 350 to 550, from 350 to 500, from 350 to 450, from 350 to
400, from 400 to
30,000, from 400 to 25,000, from 400 to 20,000, from 400 to 15,000, from 400
to 10,000, from
400 to 9,500, from 400 to 9,000, from 400 to 8,500, from 400 to 8,000, from
400 to 7,500, from
400 to 7,000, from 400 to 6,500, from 400 to 6,000, from 400 to 5,500, from
400 to 5,000, from
400 to 4,500, from 400 to 4,000, from 400 to 3,500, from 400 to 3,000, from
400 to 2,500, from
400 to 2,000, from 400 to 1,500, from 400 to 1,000, from 400 to 950, from 400
to 900, from 400
to 850, from 400 to 800, from 400 to 750, from 400 to 700, from 400 to 650,
from 400 to 600,
from 400 to 550, from 400 to 500, from 400 to 450, from 450 to 30,000, from
450 to 25,000,
from 450 to 20,000, from 450 to 15,000, from 450 to 10,000, from 450 to 9,500,
from 450 to
9,000, from 450 to 8,500, from 450 to 8,000, from 450 to 7,500, from 450 to
7,000, from 450 to
6,500, from 450 to 6,000, from 450 to 5,500, from 450 to 5,000, from 450 to
4,500, from 450 to
4,000, from 450 to 3,500, from 450 to 3,000, from 450 to 2,500, from 450 to
2,000, from 450 to
1,500, from 450 to 1,000, from 450 to 950, from 450 to 900, from 450 to 850,
from 450 to 800,
from 450 to 750, from 450 to 700, from 450 to 650, from 450 to 600, from 450
to 550, from 450
to 500, from 500 to 30,000, from 500 to 25,000, from 500 to 20,000, from 500
to 15,000, from
500 to 10,000, from 500 to 9,500, from 500 to 9,000, from 500 to 8,500, from
500 to 8,000, from
500 to 7,500, from 500 to 7,000, from 500 to 6,500, from 500 to 6,000, from
500 to 5,500, from
500 to 5,000, from 500 to 4,500, from 500 to 4,000, from 500 to 3,500, from
500 to 3,000, from
500 to 2,500, from 500 to 2,000, from 500 to 1,500, from 500 to 1,000, from
500 to 950, from
500 to 900, from 500 to 850, from 500 to 800, from 500 to 750, from 500 to
700, from 500 to
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650, from 500 to 600, from 500 to 550, from 600 to 30,000, from 600 to 25,000,
from 600 to
20,000, from 600 to 15,000, from 600 to 10,000, from 600 to 9,500, from 600 to
9,000, from 600
to 8,500, from 600 to 8,000, from 600 to 7,500, from 600 to 7,000, from 600 to
6,500, from 600
to 6,000, from 600 to 5,500, from 600 to 5,000, from 600 to 4,500, from 600 to
4,000, from 600
to 3,500, from 600 to 3,000, from 600 to 2,500, from 600 to 2,000, from 600 to
1,500, from 600
to 1,000, from 600 to 950, from 600 to 900, from 600 to 850, from 600 to 800,
from 600 to 750,
from 600 to 700, from 600 to 650, from 700 to 30,000, from 700 to 25,000, from
700 to 20,000,
from 700 to 15,000, from 700 to 10,000, from 700 to 9,500, from 700 to 9,000,
from 700 to
8,500, from 700 to 8,000, from 700 to 7,500, from 700 to 7,000, from 700 to
6,500, from 700 to
6,000, from 700 to 5,500, from 700 to 5,000, from 700 to 4,500, from 700 to
4,000, from 700 to
3,500, from 700 to 3,000, from 700 to 2,500, from 700 to 2,000, from 700 to
1,500, from 700 to
1,000, from 700 to 950, from 700 to 900, from 700 to 850, from 700 to 800,
from 700 to 750,
from 800 to 30,000, from 800 to 25,000, from 800 to 20,000, from 800 to
15,000, from 800 to
10,000, from 800 to 9,500, from 800 to 9,000, from 800 to 8,500, from 800 to
8,000, from 800 to
7,500, from 800 to 7,000, from 800 to 6,500, from 800 to 6,000, from 800 to
5,500, from 800 to
5,000, from 800 to 4,500, from 800 to 4,000, from 800 to 3,500, from 800 to
3,000, from 800 to
2,500, from 800 to 2,000, from 800 to 1,500, from 800 to 1,000, from 800 to
950, from 800 to
900, from 800 to 850, from 900 to 30,000, from 900 to 25,000, from 900 to
20,000, from 900 to
15,000, from 900 to 10,000, from 900 to 9,500, from 900 to 9,000, from 900 to
8,500, from 900
to 8,000, from 900 to 7,500, from 900 to 7,000, from 900 to 6,500, from 900 to
6,000, from 900
to 5,500, from 900 to 5,000, from 900 to 4,500, from 900 to 4,000, from 900 to
3,500, from 900
to 3,000, from 900 to 2,500, from 900 to 2,000, from 900 to 1,500, from 900 to
1,000, from 900
to 950, from 1,000 to 30,000, from 1,000 to 25,000, from 1,000 to 20,000, from
1,000 to 15,000,
from 1,000 to 10,000, from 1,000 to 9,500, from 1,000 to 9,000, from 1,000 to
8,500, from 1,000
to 8,000, from 1,000 to 7,500, from 1,000 to 7,000, from 1,000 to 6,500, from
1,000 to 6,000,
from 1,000 to 5,500, from 1,000 to 5,000, from 1,000 to 4,500, from 1,000 to
4,000, from 1,000
to 3,500, from 1,000 to 3,000, from 1,000 to 2,500, from 1,000 to 2,000, from
1,000 to 1,500,
from 2,000 to 30,000, from 2,000 to 25,000, from 2,000 to 20,000, from 2,000
to 15,000, from
2,000 to 10,000, from 2,000 to 9,500, from 2,000 to 9,000, from 2,000 to
8,500, from 2,000 to
8,000, from 2,000 to 7,500, from 2,000 to 7,000, from 2,000 to 6,500, from
2,000 to 6,000, from
2,000 to 5,500, from 2,000 to 5,000, from 2,000 to 4,500, from 2,000 to 4,000,
from 2,000 to
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3,500, from 2,000 to 3,000, from 2,000 to 2,500, from 3,000 to 30,000, from
3,000 to 25,000,
from 3,000 to 20,000, from 3,000 to 15,000, from 3,000 to 10,000, from 3,000
to 9,500, from
3,000 to 9,000, from 3,000 to 8,500, from 3,000 to 8,000, from 3,000 to 7,500,
from 3,000 to
7,000, from 3,000 to 6,500, from 3,000 to 6,000, from 3,000 to 5,500, from
3,000 to 5,000, from
3,000 to 4,500, from 3,000 to 4,000, from 3,000 to 3,500, from 4,000 to
30,000, from 4,000 to
25,000, from 4,000 to 20,000, from 4,000 to 15,000, from 4,000 to 10,000, from
4,000 to 9,500,
from 4,000 to 9,000, from 4,000 to 8,500, from 4,000 to 8,000, from 4,000 to
7,500, from 4,000
to 7,000, from 4,000 to 6,500, from 4,000 to 6,000, from 4,000 to 5,500, from
4,000 to 5,000,
from 4,000 to 4,500, from 5,000 to 30,000, from 5,000 to 25,000, from 5,000 to
20,000, from
5,000 to 15,000, from 5,000 to 10,000, from 5,000 to 9,500, from 5,000 to
9,000, from 5,000 to
8,500, from 5,000 to 8,000, from 5,000 to 7,500, from 5,000 to 7,000, from
5,000 to 6,500, from
5,000 to 6,000, from 5,000 to 5,500, from 6,000 to 30,000, from 6,000 to
25,000, from 6,000 to
20,000, from 6,000 to 15,000, from 6,000 to 10,000, from 6,000 to 9,500, from
6,000 to 9,000,
from 6,000 to 8,500, from 6,000 to 8,000, from 6,000 to 7,500, from 6,000 to
7,000, from 6,000
to 6,500, from 7,000 to 30,000, from 7,000 to 25,000, from 7,000 to 20,000,
from 7,000 to
15,000, from 7,000 to 10,000, from 7,000 to 9,500, from 7,000 to 9,000, from
7,000 to 8,500,
from 7,000 to 8,000, from 7,000 to 7,500, from 8,000 to 30,000, from 8,000 to
25,000, from
8,000 to 20,000, from 8,000 to 15,000, from 8,000 to 10,000, from 8,000 to
9,500, from 8,000 to
9,000, from 8,000 to 8,500, from 9,000 to 30,000, from 9,000 to 25,000, from
9,000 to 20,000,
from 9,000 to 15,000, from 9,000 to 10,000, from 9,000 to 9,500, from 10,000
to 30,000, from
10,000 to 25,000, from 10,000 to 20,000, from 10,000 to 15,000, from 15,000 to
30,000, from
15,000 to 25,000, from 15,000 to 20,000, from 20,000 to 30,000, from 20,000 to
25,000, or from
25,000 to 30,000.
[0011] Optionally, an inter-particle spacing for the plurality of particles
may be from 1 um to
25 m, such as from 1 um to 2 um, from 1 um to 3 um, from 1 um to 4 m, from 1
um to 5 um,
from 1 um to 6 um, from 1 um to 7 um, from 1 um to 8 m, from 1 um to 9 um,
from 1 um to
m, from 1 um to 11 um, from 1 um to 12 um, from 1 um to 13 um, from 1 um to 14
um,
from 1 um to 15 um, from 1 um to 16 um, from 1 um to 17 um, from 1 um to 18
um, from 1
um to 19 um, from 1 um to 20 um, from 1 um to 21 um, from 1 um to 22 um, from
1 um to 23
um, from 1 um to 24 um, from 2 um to 3 um, from 2 um to 4 um, from 2 um to 5
um, from 2
um to 6 um, from 2 um to 7 um, from 2 um to 8 um, from 2 um to 9 um, from 2 um
to 10 um,
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from 2 p.m to 11 p.m, from 2 p.m to 12 p.m, from 2 p.m to 13 p.m, from 2 p.m
to 14 p.m, from 2
p.m to 15 p.m, from 2 p.m to 16 p.m, from 2 p.m to 17 p.m, from 2 p.m to 18
p.m, from 2 p.m to 19
p.m, from 2 p.m to 20 p.m, from 2 p.m to 21 p.m, from 2 p.m to 22 p.m, from 2
p.m to 23 p.m, from
2 p.m to 24 m, from 2 p.m to 25 m, from 3 p.m to 4 p.m, from 3 p.m to 5 m,
from 3 [tm to 6
p.m, from 3 p.m to 7 p.m, from 3 p.m to 8 p.m, from 3 p.m to 9 p.m, from 3 p.m
to 10 p.m, from 3
p.m to 11 p.m, from 3 p.m to 12 p.m, from 3 p.m to 13 p.m, from 3 p.m to 14
p.m, from 3 p.m to 15
p.m, from 3 p.m to 16 p.m, from 3 p.m to 17 p.m, from 3 p.m to 18 p.m, from 3
p.m to 19 p.m, from
3 p.m to 20 m, from 3 p.m to 21 m, from 3 p.m to 22 p.m, from 3 p.m to 23
p.m, from 3 p.m to
24 m, from 3 p.m to 25 p.m, from 4 p.m to 5 p.m, from 4 p.m to 6 m, from 4
p.m to 7 p.m, from
4 p.m to 8 m, from 4 p.m to 9 p.m, from 4 p.m to 10 m, from 4 p.m to 11 p.m,
from 4 p.m to 12
p.m, from 4 p.m to 13 p.m, from 4 p.m to 14 p.m, from 4 p.m to 15 p.m, from 4
p.m to 16 p.m, from
4 p.m to 17 m, from 4 p.m to 18 m, from 4 p.m to 19 p.m, from 4 p.m to 20
p.m, from 4 p.m to
21 m, from 4 p.m to 22 p.m, from 4 p.m to 23 p.m, from 4 p.m to 24 p.m, from
4 p.m to 25 p.m,
from 5 p.m to 6 p.m, from 5 p.m to 7 p.m, from 5 p.m to 8 m, from 5 p.m to 9
p.m, from 5 p.m to
m, from 5 p.m to 11 p.m, from 5 p.m to 12 p.m, from 5 p.m to 13 p.m, from 5
p.m to 14 p.m,
from 5 p.m to 15 p.m, from 5 p.m to 16 p.m, from 5 p.m to 17 p.m, from 5 p.m
to 18 p.m, from 5
p.m to 19 p.m, from 5 p.m to 20 p.m, from 5 p.m to 21 p.m, from 5 p.m to 22
p.m, from 5 p.m to 23
p.m, from 5 p.m to 24 p.m, from 5 p.m to 25 p.m, from 6 p.m to 7 p.m, from 6
p.m to 8 p.m, from 6
p.m to 9 p.m, from 6 p.m to 10 p.m, from 6 p.m to 11 p.m, from 6 p.m to 12
p.m, from 6 p.m to 13
p.m, from 6 p.m to 14 p.m, from 6 p.m to 15 p.m, from 6 p.m to 16 p.m, from 6
p.m to 17 p.m, from
6 p.m to 18 m, from 6 p.m to 19 m, from 6 p.m to 20 p.m, from 6 p.m to 21
p.m, from 6 p.m to
22 m, from 6 p.m to 23 p.m, from 6 p.m to 24 p.m, from 6 p.m to 25 p.m, from
7 p.m to 8 p.m,
from 7 p.m to 9 p.m, from 7 p.m to 10 p.m, from 7 p.m to 11 p.m, from 7 p.m to
12 p.m, from 7 p.m
to 13 p.m, from 7 p.m to 14 p.m, from 7 p.m to 15 p.m, from 7 p.m to 16 p.m,
from 7 p.m to 17 p.m,
from 7 p.m to 18 p.m, from 7 p.m to 19 p.m, from 7 p.m to 20 p.m, from 7 p.m
to 21 p.m, from 7
p.m to 22 p.m, from 7 p.m to 23 p.m, from 7 p.m to 24 p.m, from 7 p.m to 25
p.m, from 8 p.m to 9
p.m, from 8 p.m to 10 p.m, from 8 p.m to 11 p.m, from 8 p.m to 12 p.m, from 8
p.m to 13 p.m, from
8 p.m to 14 m, from 8 p.m to 15 m, from 8 p.m to 16 p.m, from 8 p.m to 17
p.m, from 8 p.m to
18 m, from 8 p.m to 19 p.m, from 8 p.m to 20 p.m, from 8 p.m to 21 p.m, from
8 p.m to 22 p.m,
from 8 p.m to 23 p.m, from 8 p.m to 24 p.m, from 8 p.m to 25 p.m, from 9 p.m
to 10 p.m, from 9
p.m to 11 p.m, from 9 p.m to 12 p.m, from 9 p.m to 13 p.m, from 9 p.m to 14
p.m, from 9 p.m to 15

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[tm, from 9 [tm to 16 [tm, from 9 [tm to 17 [tm, from 9 [tm to 18 [tm, from 9
[tm to 19 [tm, from
9 [tm to 20 m, from 9 [tm to 21 m, from 9 [tm to 22 [tm, from 9 [tm to 23
[tm, from 9 [tm to
24 m, from 9 [tm to 25 [tm, from 10 [tm to 11 [tm, from 10 [tm to 12 m, from
10 [tm to 13
[tm, from 10 [tm to 14 [tm, from 10 [tm to 15 [tm, from 10 [tm to 16 [tm, from
10 [tm to 17 [tm,
from 10 [tm to 18 m, from 10 [tm to 19 [tm, from 10 [tm to 20 m, from 10 [tm
to 21 [tm, from
[tm to 22 m, from 10 [tm to 23 [tm, from 10 [tm to 24 [tm, from 10 [tm to 25
[tm, from 11
p.m to 12 [tm, from 11 p.m to 13 [tm, from 11 p.m to 14 [tm, from 11 p.m to 15
[tm, from 11 [tm
to 16 [tm, from 11 [tm to 17 [tm, from 11 [tm to 18 [tm, from 11 [tm to 19
[tm, from 11 [tm to 20
[tm, from 11 [tm to 21 [tm, from 11 [tm to 22 [tm, from 11 [tm to 23 [tm, from
11 [tm to 24 [tm,
from 11 [tm to 25 m, from 12 [tm to 13 [tm, from 12 [tm to 14 m, from 12 [tm
to 15 [tm, from
12 [tm to 16 m, from 12 [tm to 17 [tm, from 12 [tm to 18 [tm, from 12 [tm to
19 [tm, from 12
[tm to 20 [tm, from 12 [tm to 21 [tm, from 12 [tm to 22 [tm, from 12 [tm to 23
[tm, from 12 [tm
to 24 [tm, from 12 [tm to 25 [tm, from 13 [tm to 14 [tm, from 13 [tm to 15
[tm, from 13 [tm to 16
[tm, from 13 [tm to 17 [tm, from 13 [tm to 18 [tm, from 13 [tm to 19 [tm, from
13 [tm to 20 [tm,
from 13 [tm to 21 m, from 13 [tm to 22 [tm, from 13 [tm to 23 m, from 13 [tm
to 24 [tm, from
13 [tm to 25 m, from 14 [tm to 15 [tm, from 14 [tm to 16 [tm, from 14 [tm to
17 [tm, from 14
[tm to 18 [tm, from 14 [tm to 19 [tm, from 14 [tm to 20 [tm, from 14 [tm to 21
[tm, from 14 [tm
to 22 [tm, from 14 [tm to 23 [tm, from 14 [tm to 24 [tm, from 14 [tm to 25
[tm, from 15 [tm to 16
[tm, from 15 [tm to 17 [tm, from 15 [tm to 18 [tm, from 15 [tm to 19 [tm, from
15 [tm to 20 [tm,
from 15 [tm to 21 m, from 15 [tm to 22 [tm, from 15 [tm to 23 m, from 15 [tm
to 24 [tm, from
[tm to 25 m, from 16 [tm to 17 [tm, from 16 [tm to 18 [tm, from 16 [tm to 19
[tm, from 16
[tm to 20 [tm, from 16 [tm to 21 [tm, from 16 [tm to 22 [tm, from 16 [tm to 23
[tm, from 16 [tm
to 24 [tm, from 16 [tm to 25 [tm, from 17 [tm to 18 [tm, from 17 [tm to 19
[tm, from 17 [tm to 20
[tm, from 17 [tm to 21 [tm, from 17 [tm to 22 [tm, from 17 [tm to 23 [tm, from
17 [tm to 24 [tm,
from 17 [tm to 25 m, from 18 [tm to 19 [tm, from 18 [tm to 20 m, from 18 [tm
to 21 [tm, from
18 [tm to 22 m, from 18 [tm to 23 [tm, from 18 [tm to 24 [tm, from 18 [tm to
25 [tm, from 19
[tm to 20 [tm, from 19 [tm to 21 [tm, from 19 [tm to 22 [tm, from 19 [tm to 23
[tm, from 19 [tm
to 24 [tm, from 19 [tm to 25 [tm, from 20 [tm to 21 [tm, from 20 [tm to 22
[tm, from 20 [tm to 23
[tm, from 20 [tm to 24 [tm, from 20 [tm to 25 [tm, from 21 [tm to 22 [tm, from
21 [tm to 23 [tm,
from 21 [tm to 24 m, from 21 [tm to 25 [tm, from 22 [tm to 23 m, from 22 [tm
to 24 [tm, from
22 [tm to 25 m, from 23 [tm to 24 [tm, from 23 [tm to 25 [tm, or from 24 [tm
to 25 [tm.
11

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[0012] Optionally, the plurality of particles may have diameters of from
100 nm to 50 p.m or
500 nm to 10 p.m or 100 nm to 1 p.m, such as from 100 nm to 200 nm, from 100
nm to 300 nm,
from 100 nm to 400 nm, from 100 nm to 500 nm, from 100 nm to 600 nm, from 100
nm to 700
nm, from 100 nm to 800 nm, from 100 nm to 900 nm, from 200 nm to 300 nm, from
200 nm to
400 nm, from 200 nm to 500 nm, from 200 nm to 600 nm, from 200 nm to 700 nm,
from 200 nm
to 800 nm, from 200 nm to 900 nm, from 200 nm to 1 p.m, from 300 nm to 400 nm,
from 300 nm
to 500 nm, from 300 nm to 600 nm, from 300 nm to 700 nm, from 300 nm to 800
nm, from 300
nm to 900 nm, from 300 nm to 1 p.m, from 400 nm to 500 nm, from 400 nm to 600
nm, from 400
nm to 700 nm, from 400 nm to 800 nm, from 400 nm to 900 nm, from 400 nm to 1
p.m, from 500
nm to 600 nm, from 500 nm to 700 nm, from 500 nm to 800 nm, from 500 nm to 900
nm, from
500 nm to 1 p.m, from 600 nm to 700 nm, from 600 nm to 800 nm, from 600 nm to
900 nm, from
600 nm to 1 p.m, from 700 nm to 800 nm, from 700 nm to 900 nm, from 700 nm to
1 p.m, from
800 nm to 900 nm, from 800 nm to 1 p.m, or from 900 nm to 1 pm. Optionally,
the plurality of
particles may have diameters of from 500 nm to 50 p.m.
[0013] The composition of the aluminum alloy for the aluminum alloy
products described
above may optionally comprise from 0.1 wt. % to 1.0 wt. % iron (Fe), from 0.05
wt. % to 0.8 wt.
% silicon (Si), from 0.2 wt. % to 2.0 wt. % manganese (Mn), from 0.2 wt. % to
2.0 wt. %
magnesium (Mg), up to 0.5 wt. % copper (Cu), up to 0.05 wt. % zinc (Zn), and
aluminum (Al).
The composition of the aluminum alloy for the aluminum alloy products
described above may
comprise up to 0.15 wt. % impurities. Optionally, a remainder may be aluminum.
Optionally,
the composition of the aluminum alloy for the aluminum alloy products
described above may
comprise from 0.2 wt. % to 0.8 wt. % iron, from 0.10 wt. % to 0.7 wt. %
silicon, from 0.6 wt. %
to 1.0 wt. % manganese, from 0.7 wt. % to 1.0 wt. % magnesium, up to 0.25 wt.
% copper, up to
0.2 wt. % zinc, up to 0.10 wt. % titanium (Ti), up to 0.10 wt. % chromium
(Cr), up to 0.10 wt. %
zirconium (Zr), up to 0.10 wt. % vanadium (V), and aluminum. Optionally, the
composition of
the aluminum alloy for the aluminum alloy products described above may
comprise from 0.3 wt.
% to 0.7 wt. % iron, from 0.15 wt. % to 0.5 wt. % silicon, from 0.8 wt. % to
1.2 wt. %
manganese, from 0.9 wt. % to 1.2 wt. % magnesium, from 0.1 wt. % to 0.2 wt. %
copper, up to
0.15 wt. % zinc, up to 0.08 wt. % titanium, up to 0.05 wt. % chromium, up to
0.05 wt. %
zirconium, up to 0.05 wt. % vanadium, and aluminum.
12

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[0014] In some embodiments, the aluminum alloy may include a 3xxx series
aluminum
alloy. In such embodiments, the aluminum alloy may optionally comprise from
0.8 wt. % to 1.4
wt. % magnesium, from 0.8 wt. % to 1.3 wt. % manganese, up to 0.25 wt. %
copper, from 0.25
wt. % to 0.7 wt. % iron, up to 0.7 wt.%, and up to 0.25 wt. % zinc. The
remainder may be
aluminum.
[0015] The aluminum alloys for the aluminum alloy products described above
may
optionally include a-phase intermetallic particles comprising from 0.5% to
4.0% by volume of
the aluminum alloy, such as from 0.5 to 1.0, from 0.5 to 1.5, from 0.5 to 2.0,
from 0.5 to 2.5,
from 0.5 to 3.0, from 0.5 to 3.5, from 1.0 to 1.5, from 1.0 to 2.0, from 1.0
to 2.5, from 1.0 to 3.0,
from 1.0 to 3.5, from 1.0 to 4.0, from 1.5 to 2.0, from 1.5 to 2.5, from 1.5
to 3.0, from 1.5 to 3.5,
from 1.5 to 4.0, from 2.0 to 2.5, from 2.0 to 3.0, from 2.0 to 3.5, from 2.0
to 4.0, from 2.5 to 3.0,
from 2.5 to 3.5, from 2.5 to 4.0, from 3.0 to 3.5, from 3.0 to 4.0, or from
3.5 to 4Ø The
aluminum alloys for the aluminum alloy products described above may include 0-
phase
intermetallic particles comprising from 0% to 2.0% by volume of the aluminum
alloy, such as
from 0 to 0.5, from 0 to 1.0, from 0 to 1.5, from 0.5 to 1.0, from 0.5 to 1.5,
from 0.5 to 2.0, from
1.0 to 1.5, from 1.0 to 2.0, or from 1.5 to 2Ø Optionally, the aluminum
alloys for the aluminum
alloy products described above may include a-phase intermetallic particles
comprising
A115(Fe,Mn)3Si2. Optionally, the aluminum alloys for the aluminum alloy
products described
above may include 0-phase intermetallic particles comprising A16(Fe,Mn).
[0016] Optionally, the aluminum alloys for the aluminum alloy products
described above
may include a ratio of an a-phase intermetallic particle number density to a 0-
phase intermetallic
particle number density is from 0.2 to 1,000 or a ratio of a volume % of the a-
phase intermetallic
particles to a volume % of the 0-phase intermetallic particles is from 0.6 to
1,000.
[0017] Optionally, the aluminum alloys for the aluminum alloy products
described above
may include a ratio of the a-phase intermetallic particle number density to
the 0-phase
intermetallic particle number density from 0.3 to 3, such as from 0.3 to 0.4,
from 0.3 to 0.5, from
0.3 to 0.6, from 0.3 to 0.7, from 0.3 to 0.8, from 0.3 to 0.9, from 0.3 to
1.0, from 0.3 to 1.1, from
0.3 to 1.2, from 0.3 to 1.3, from 0.3 to 1.4, from 0.3 to 1.5, from 0.3 to
1.6, from 0.3 to 1.7, from
0.3 to 1.8, from 0.3 to 1.9, from 0.3 to 2.0, from 0.3 to 2.1, from 0.3 to
2.2, from 0.3 to 2.3, from
0.3 to 2.4, from 0.3 to 2.5, from 0.3 to 2.6, from 0.3 to 2.7, from 0.3 to
2.8, from 0.3 to 2.9, from
0.4 to 0.5, from 0.4 to 0.6, from 0.4 to 0.7, from 0.4 to 0.8, from 0.4 to
0.9, from 0.4 to 1.0, from
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0.4 to 1.1, from 0.4 to 1.2, from 0.4 to 1.3, from 0.4 to 1.4, from 0.4 to
1.5, from 0.4 to 1.6, from
0.4 to 1.7, from 0.4 to 1.8, from 0.4 to 1.9, from 0.4 to 2.0, from 0.4 to
2.1, from 0.4 to 2.2, from
0.4 to 2.3, from 0.4 to 2.4, from 0.4 to 2.5, from 0.4 to 2.6, from 0.4 to
2.7, from 0.4 to 2.8, from
0.4 to 2.9, from 0.4 to 3, from 0.5 to 0.6, from 0.5 to 0.7, from 0.5 to 0.8,
from 0.5 to 0.9, from
0.5 to 1.0, from 0.5 to 1.1, from 0.5 to 1.2, from 0.5 to 1.3, from 0.5 to
1.4, from 0.5 to 1.5, from
0.5 to 1.6, from 0.5 to 1.7, from 0.5 to 1.8, from 0.5 to 1.9, from 0.5 to
2.0, from 0.5 to 2.1, from
0.5 to 2.2, from 0.5 to 2.3, from 0.5 to 2.4, from 0.5 to 2.5, from 0.5 to
2.6, from 0.5 to 2.7, from
0.5 to 2.8, from 0.5 to 2.9, from 0.5 to 3, from 0.6 to 0.7, from 0.6 to 0.8,
from 0.6 to 0.9, from
0.6 to 1.0, from 0.6 to 1.1, from 0.6 to 1.2, from 0.6 to 1.3, from 0.6 to
1.4, from 0.6 to 1.5, from
0.6 to 1.6, from 0.6 to 1.7, from 0.6 to 1.8, from 0.6 to 1.9, from 0.6 to
2.0, from 0.6 to 2.1, from
0.6 to 2.2, from 0.6 to 2.3, from 0.6 to 2.4, from 0.6 to 2.5, from 0.6 to
2.6, from 0.6 to 2.7, from
0.6 to 2.8, from 0.6 to 2.9, from 0.6 to 3, from 0.7 to 0.8, from 0.7 to 0.9,
from 0.7 to 1.0, from
0.7 to 1.1, from 0.7 to 1.2, from 0.7 to 1.3, from 0.7 to 1.4, from 0.7 to
1.5, from 0.7 to 1.6, from
0.7 to 1.7, from 0.7 to 1.8, from 0.7 to 1.9, from 0.7 to 2.0, from 0.7 to
2.1, from 0.7 to 2.2, from
0.7 to 2.3, from 0.7 to 2.4, from 0.7 to 2.5, from 0.7 to 2.6, from 0.7 to
2.7, from 0.7 to 2.8, from
0.7 to 2.9, from 0.7 to 3, from 0.8 to 0.9, from 0.8 to 1.0, from 0.8 to 1.1,
from 0.8 to 1.2, from
0.8 to 1.3, from 0.8 to 1.4, from 0.8 to 1.5, from 0.8 to 1.6, from 0.8 to
1.7, from 0.8 to 1.8, from
0.8 to 1.9, from 0.8 to 2.0, from 0.8 to 2.1, from 0.8 to 2.2, from 0.8 to
2.3, from 0.8 to 2.4, from
0.8 to 2.5, from 0.8 to 2.6, from 0.8 to 2.7, from 0.8 to 2.8, from 0.8 to
2.9, from 0.8 to 3, from
0.9 to 1.0, from 0.9 to 1.1, from 0.9 to 1.2, from 0.9 to 1.3, from 0.9 to
1.4, from 0.9 to 1.5, from
0.9 to 1.6, from 0.9 to 1.7, from 0.9 to 1.8, from 0.9 to 1.9, from 0.9 to
2.0, from 0.9 to 2.1, from
0.9 to 2.2, from 0.9 to 2.3, from 0.9 to 2.4, from 0.9 to 2.5, from 0.9 to
2.6, from 0.9 to 2.7, from
0.9 to 2.8, from 0.9 to 2.9, from 0.9 to 3, from 1.0 to 1.1, from 1.0 to 1.2,
from 1.0 to 1.3, from
1.0 to 1.4, from 1.0 to 1.5, from 1.0 to 1.6, from 1.0 to 1.7, from 1.0 to
1.8, from 1.0 to 1.9, from
1.0 to 2.0, from 1.0 to 2.1, from 1.0 to 2.2, from 1.0 to 2.3, from 1.0 to
2.4, from 1.0 to 2.5, from
1.0 to 2.6, from 1.0 to 2.7, from 1.0 to 2.8, from 1.0 to 2.9, from 1.0 to 3,
from 1.1 to 1.2, from
1.1 to 1.3, from 1.1 to 1.4, from 1.1 to 1.5, from 1.1 to 1.6, from 1.1 to
1.7, from 1.1 to 1.8, from
1.1 to 1.9, from 1.1 to 2.0, from 1.1 to 2.1, from 1.1 to 2.2, from 1.1 to
2.3, from 1.1 to 2.4, from
1.1 to 2.5, from 1.1 to 2.6, from 1.1 to 2.7, from 1.1 to 2.8, from 1.1 to
2.9, from 1.1 to 3, from
1.2 to 1.3, from 1.2 to 1.4, from 1.2 to 1.5, from 1.2 to 1.6, from 1.2 to
1.7, from 1.2 to 1.8, from
1.2 to 1.9, from 1.2 to 2.0, from 1.2 to 2.1, from 1.2 to 2.2, from 1.2 to
2.3, from 1.2 to 2.4, from
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1.2 to 2.5, from 1.2 to 2.6, from 1.2 to 2.7, from 1.2 to 2.8, from 1.2 to
2.9, from 1.2 to 3, from
1.3 to 1.4, from 1.3 to 1.5, from 1.3 to 1.6, from 1.3 to 1.7, from 1.3 to
1.8, from 1.3 to 1.9, from
1.3 to 2.0, from 1.3 to 2.1, from 1.3 to 2.2, from 1.3 to 2.3, from 1.3 to
2.4, from 1.3 to 2.5, from
1.3 to 2.6, from 1.3 to 2.7, from 1.3 to 2.8, from 1.3 to 2.9, from 1.3 to 3,
from 1.4 to 1.5, from
1.4 to 1.6, from 1.4 to 1.7, from 1.4 to 1.8, from 1.4 to 1.9, from 1.4 to
2.0, from 1.4 to 2.1, from
1.4 to 2.2, from 1.4 to 2.3, from 1.4 to 2.4, from 1.4 to 2.5, from 1.4 to
2.6, from 1.4 to 2.7, from
1.4 to 2.8, from 1.4 to 2.9, from 1.4 to 3, from 1.5 to 1.6, from 1.5 to 1.7,
from 1.5 to 1.8, from
1.5 to 1.9, from 1.5 to 2.0, from 1.5 to 2.1, from 1.5 to 2.2, from 1.5 to
2.3, from 1.5 to 2.4, from
1.5 to 2.5, from 1.5 to 2.6, from 1.5 to 2.7, from 1.5 to 2.8, from 1.5 to
2.9, from 1.5 to 3, from
1.6 to 1.7, from 1.6 to 1.8, from 1.6 to 1.9, from 1.6 to 2.0, from 1.6 to
2.1, from 1.6 to 2.2, from
1.6 to 2.3, from 1.6 to 2.4, from 1.6 to 2.5, from 1.6 to 2.6, from 1.6 to
2.7, from 1.6 to 2.8, from
1.6 to 2.9, from 1.6 to 3, from 1.7 to 1.8, from 1.7 to 1.9, from 1.7 to 2.0,
from 1.7 to 2.1, from
1.7 to 2.2, from 1.7 to 2.3, from 1.7 to 2.4, from 1.7 to 2.5, from 1.7 to
2.6, from 1.7 to 2.7, from
1.7 to 2.8, from 1.7 to 2.9, from 1.7 to 3, from 1.8 to 1.9, from 1.8 to 2.0,
from 1.8 to 2.1, from
1.8 to 2.2, from 1.8 to 2.3, from 1.8 to 2.4, from 1.8 to 2.5, from 1.8 to
2.6, from 1.8 to 2.7, from
1.8 to 2.8, from 1.8 to 2.9, from 1.8 to 3, from 1.9 to 2.0, from 1.9 to 2.1,
from 1.9 to 2.2, from
1.9 to 2.3, from 1.9 to 2.4, from 1.9 to 2.5, from 1.9 to 2.6, from 1.9 to
2.7, from 1.9 to 2.8, from
1.9 to 2.9, from 1.9 to 3, from 2.0 to 2.1, from 2.0 to 2.2, from 2.0 to 2.3,
from 2.0 to 2.4, from
2.0 to 2.5, from 2.0 to 2.6, from 2.0 to 2.7, from 2.0 to 2.8, from 2.0 to
2.9, from 2.0 to 3, from
2.1 to 2.2, from 2.1 to 2.3, from 2.1 to 2.4, from 2.1 to 2.5, from 2.1 to
2.6, from 2.1 to 2.7, from
2.1 to 2.8, from 2.1 to 2.9, from 2.1 to 3, from 2.2 to 2.3, from 2.2 to 2.4,
from 2.2 to 2.5, from
2.2 to 2.6, from 2.2 to 2.7, from 2.2 to 2.8, from 2.2 to 2.9, from 2.2 to 3,
from 2.3 to 2.4, from
2.3 to 2.5, from 2.3 to 2.6, from 2.3 to 2.7, from 2.3 to 2.8, from 2.3 to
2.9, from 2.3 to 3, from
2.4 to 2.5, from 2.4 to 2.6, from 2.4 to 2.7, from 2.4 to 2.8, from 2.4 to
2.9, from 2.4 to 3, from
2.5 to 2.6, from 2.5 to 2.6, from 2.5 to 2.7, from 2.5 to 2.8, from 2.5 to
2.9, from 2.5 to 3, from
2.6 to 2.7, from 2.6 to 2.8, from 2.6 to 2.9, from 2.6 to 3, from 2.7 to 2.8,
from 2.7 to 2.9, from
2.7 to 3, from 2.8 to 2.9, from 2.8 to 3, or from 2.9 to 3.
[0018] Optionally, the aluminum alloy products described above may include
a plurality of
particles, where 80 percent or more of the inter-particle spacings between
particles are from 5
p.m to 15 p.m. Optionally, the plurality of particles may include iron-
containing particles, such as

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iron-containing particles where a majority have a diameter from 1 p.m to 40
p.m. Optionally, the
iron-containing particles may comprise from 1% to 4% of a total volume of the
aluminum alloy.
[0019] Optionally, the aluminum alloys for the aluminum alloy products
described above
may comprise or further comprise manganese-containing dispersoids, such as
where a majority
of the manganese-containing dispersoids have a diameter of from 10 nm to 1.5
p.m. Optionally,
the manganese-containing dispersoids may comprise up to 1% of a total volume
of the aluminum
alloy. In some cases, dispersoids are not included in counts of particles of
other types, such as a-
phase particles and/or 0-phase particles, and/or may optionally be counted
separately from other
types of particles.
[0020] Metal products, such as aluminum alloy products, are also described
herein. In some
embodiments, a metal product may be prepared by any of the methods described
herein. In some
specific embodiments, a metal product comprises a homogenized 3xxx series
aluminum alloy
including aluminum, iron, magnesium, manganese, and silicon, such as with a
ratio of a silicon
wt. % in the homogenized 3xxx series aluminum alloy to an iron wt. % in the
homogenized 3xxx
series aluminum alloy of from 0.5 to 1.0, and including a-phase intermetallic
particles
comprising aluminum, silicon, and one or more of iron or manganese and
optionally 0-phase
intermetallic particles comprising aluminum and one or more of iron or
manganese, with at least
a portion of the a-phase intermetallic particles corresponding to 0-phase
intermetallic particles
transformed during homogenization of the homogenized 3xxx series aluminum
alloy. Optionally
a ratio of a volume % and/or a number density of the a-phase intermetallic
particles to a volume
% or a number density of the 0-phase intermetallic particles is from 0.6 to
1000, or more.
[0021] In another aspect, methods of making aluminum alloy products are
described. An
example method of this aspect comprises preparing a cast aluminum alloy
product comprising an
aluminum alloy, such as an aluminum alloy comprising aluminum, iron,
magnesium, manganese,
and silicon; and homogenizing the cast aluminum alloy product to form a
homogenized
aluminum alloy product. Various homogenization conditions are useful with the
methods
described herein. Optionally, homogenizing may include heating the cast
aluminum alloy
product to a homogenization temperature, such as a homogenization temperature
that is between
500 C to 650 C, such as from 500 C to 510 C, from 500 C to 520 C, from
500 C to 530
C, from 500 C to 540 C, from 500 C to 550 C, from 500 C to 560 C, from
500 C to 570
C, from 500 C to 575 C, from 500 C to 580 C, from 500 C to 585 C, from
500 C to 590
16

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C, from 500 C to 600 C, from 500 C to 610 C, from 500 C to 615 C, from
500 C to 620
C, from 500 C to 630 C, from 500 C to 640 C, from 510 C to 520 C, from
510 C to 530
C, from 510 C to 540 C, from 510 C to 550 C, from 510 C to 560 C, from
510 C to 570
C, from 510 C to 575 C, from 510 C to 580 C, from 510 C to 585 C, from 510
C to 590
C, from 510 C to 600 C, from 510 C to 610 C, from 510 C to 615 C, from
510 C to 620
C, from 510 C to 630 C, from 510 C to 640 C, from 510 C to 650 C, from 520
C to 530
C, from 520 C to 540 C, from 520 C to 550 C, from 520 C to 560 C, from
520 C to 570
C, from 520 C to 575 C, from 520 C to 580 C, from 520 C to 585 C, from
520 C to 590
C, from 520 C to 600 C, from 520 C to 610 C, from 520 C to 615 C, from
520 C to 620
C, from 520 C to 630 C, from 520 C to 640 C, from 520 C to 650 C, from
530 C to 540
C, from 530 C to 550 C, from 530 C to 560 C, from 530 C to 570 C, from
530 C to 575
C, from 530 C to 580 C, from 530 C to 585 C, from 530 C to 590 C, from
530 C to 600
C, from 530 C to 610 C, from 530 C to 615 C, from 530 C to 620 C, from
530 C to 630
C, from 530 C to 640 C, from 530 C to 650 C, from 540 C to 550 C, from
540 C to 560
C, from 540 C to 570 C, from 540 C to 575 C, from 540 C to 580 C, from
540 C to 585
C, from 540 C to 590 C, from 540 C to 600 C, from 540 C to 610 C, from
540 C to 615
C, from 540 C to 620 C, from 540 C to 630 C, from 540 C to 640 C, from
540 C to 650
C, from 550 C to 560 C, from 550 C to 570 C, from 550 C to 575 C, from
550 C to 580
C, from 550 C to 585 C, from 550 C to 590 C, from 550 C to 600 C, from
550 C to 610
C, from 550 C to 615 C, from 550 C to 620 C, from 550 C to 630 C, from
550 C to 640
C, from 550 C to 650 C, from 560 C to 570 C, from 560 C to 575 C, from
560 C to 580
C, from 560 C to 585 C, from 560 C to 590 C, from 560 C to 600 C, from
560 C to 610
C, from 560 C to 615 C, from 560 C to 620 C, from 560 C to 630 C, from
560 C to 640
C, from 560 C to 650 C, from 570 C to 575 C, from 570 C to 580 C, from
570 C to 585
C, from 570 C to 590 C, from 570 C to 600 C, from 570 C to 610 C, from
570 C to 615
C, from 570 C to 620 C, from 570 C to 630 C, from 570 C to 640 C, from
570 C to 650
C, from 575 C to 580 C, from 575 C to 585 C, from 575 C to 590 C, from
575 C to 600
C, from 575 C to 610 C, from 575 C to 615 C, from 575 C to 620 C, from
575 C to 630
C, from 575 C to 640 C, from 575 C to 650 C, from 580 C to 585 C, from
580 C to 590
C, from 580 C to 600 C, from 580 C to 610 C, from 580 C to 615 C, from
580 C to 620
C, from 580 C to 630 C, from 580 C to 640 C, from 580 C to 650 C, from
585 C to 590
17

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C, from 585 C to 600 C, from 585 C to 610 C, from 585 C to 615 C, from
585 C to 620
C, from 585 C to 630 C, from 585 C to 640 C, from 585 C to 650 C, from
590 C to 600
C, from 590 C to 610 C, from 590 C to 615 C, from 590 C to 620 C, from
590 C to 630
C, from 590 C to 640 C, from 590 C to 650 C, from 600 C to 610 C, from
600 C to 615
C, from 600 C to 620 C, from 600 C to 630 C, from 600 C to 640 C, from
600 C to 650
C, from 610 C to 615 C, from 610 C to 620 C, from 610 C to 630 C, from
610 C to 640
C, from 610 C to 650 C, from 615 C to 620 C, from 615 C to 630 C, from
615 C to 640
C, from 615 C to 650 C, from 620 C to 630 C, from 620 C to 640 C, from
620 C to 650
C, from 630 C to 640 C, from 630 C to 650 C, or from 640 C to 650 C. The
homogenization temperature may optionally be within 75 C of a solidus
temperature of the
aluminum alloy, such as within 70 C of a solidus temperature of the aluminum
alloy, within 65
C of a solidus temperature of the aluminum alloy, within 60 C of a solidus
temperature of the
aluminum alloy, within 55 C of a solidus temperature of the aluminum alloy,
within 50 C of a
solidus temperature of the aluminum alloy, within 45 C of a solidus
temperature of the
aluminum alloy, within 40 C of a solidus temperature of the aluminum alloy,
within 35 C of a
solidus temperature of the aluminum alloy, within 30 C of a solidus
temperature of the
aluminum alloy, within 25 C of a solidus temperature of the aluminum alloy,
within 20 C of a
solidus temperature of the aluminum alloy, within 15 C of a solidus
temperature of the
aluminum alloy, within 10 C of a solidus temperature of the aluminum alloy,
or within 5 C of a
solidus temperature of the aluminum alloy.
[0022] During soaking, the cast aluminum alloy product may optionally be at
the
homogenization temperature (i.e., soaking) for a time duration from 0.1 hours
to 36 hours or
from 12 hours to 36 hours, such as from 0.1 hours to 0.5 hours, from 0.1 hours
to 1 hour, from
0.1 hours to 1.5 hours, from 0.1 hours to 2 hours, from 0.1 hours to 2.5
hours, from 0.1 hours to 3
hours, from 0.1 hours to 3.5 hours, from 0.1 hours to 4 hours, from 0.1 hours
to 4.5 hours, from
0.1 hours to 5 hours, from 0.1 hours to 5.5 hours, from 0.1 hours to 6 hours,
from 0.1 hours to 6.5
hours, from 0.1 hours to 7 hours, from 0.1 hours to 7.5 hours, from 0.1 hours
to 8 hours, from 0.1
hours to 8.5 hours, from 0.1 hours to 9 hours, from 0.1 hours to 9.5 hours,
from 0.1 hours to 10
hours, from 0.1 hours to 10.5 hours, from 0.1 hours to 11 hours, from 0.1
hours to 11.5 hours,
from 0.1 hours to 12 hours, from 0.1 hours to 12.5 hours, from 0.1 hours to 13
hours, from 0.1
hours to 13.5 hours, from 0.1 hours to 14 hours, from 0.1 hours to 14.5 hours,
from 0.1 hours to
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15 hours, from 0.1 hours to 15.5 hours, from 0.1 hours to 16 hours, from 0.1
hours to 16.5 hours,
from 0.1 hours to 17 hours, from 0.1 hours to 17.5 hours, from 0.1 hours to 18
hours, from 0.1
hours to 18.5 hours, from 0.1 hours to 19 hours, from 0.1 hours to 19.5 hours,
from 0.1 hours to
20 hours, from 0.1 hours to 20.5 hours, from 0.1 hours to 21 hours, from 0.1
hours to 21.5 hours,
from 0.1 hours to 22 hours, from 0.1 hours to 22.5 hours, from 0.1 hours to 23
hours, from 0.1
hours to 23.5 hours, from 0.1 hours to 24 hours, from 0.1 hours to 25 hours,
from 0.1 hours to 26
hours, from 0.1 hours to 27 hours, from 0.1 hours to 28 hours, from 0.1 hours
to 29 hours, from
0.1 hours to 30 hours, from 0.1 hours to 31 hours, from 0.1 hours to 32 hours,
from 0.1 hours to
33 hours, from 0.1 hours to 34 hours, from 0.1 hours to 35 hours, from 0.1
hours to 36 hours,
from 0.5 hours to 1 hour, from 0.5 hours to 1.5 hours, from 0.5 hours to 2
hours, from 0.5 hours
to 2.5 hours, from 0.5 hours to 3 hours, from 0.5 hours to 3.5 hours, from 0.5
hours to 4 hours,
from 0.5 hours to 4.5 hours, from 0.5 hours to 5 hours, from 0.5 hours to 5.5
hours, from 0.5
hours to 6 hours, from 0.5 hours to 6.5 hours, from 0.5 hours to 7 hours, from
0.5 hours to 7.5
hours, from 0.5 hours to 8 hours, from 0.5 hours to 8.5 hours, from 0.5 hours
to 9 hours, from 0.5
hours to 9.5 hours, from 0.5 hours to 10 hours, from 0.5 hours to 10.5 hours,
from 0.5 hours to 11
hours, from 0.5 hours to 11.5 hours, from 0.5 hours to 12 hours, from 0.5
hours to 12.5 hours,
from 0.5 hours to 13 hours, from 0.5 hours to 13.5 hours, from 0.5 hours to 14
hours, from 0.5
hours to 14.5 hours, from 0.5 hours to 15 hours, from 0.5 hours to 15.5 hours,
from 0.5 hours to
16 hours, from 0.5 hours to 16.5 hours, from 0.5 hours to 17 hours, from 0.5
hours to 17.5 hours,
from 0.5 hours to 18 hours, from 0.5 hours to 18.5 hours, from 0.5 hours to 19
hours, from 0.5
hours to 19.5 hours, from 0.5 hours to 20 hours, from 0.5 hours to 20.5 hours,
from 0.5 hours to
21 hours, from 0.5 hours to 21.5 hours, from 0.5 hours to 22 hours, from 0.5
hours to 22.5 hours,
from 0.5 hours to 23 hours, from 0.5 hours to 23.5 hours, from 0.5 hours to 24
hours, from 0.5
hours to 25 hours, from 0.5 hours to 26 hours, from 0.5 hours to 27 hours,
from 0.5 hours to 28
hours, from 0.5 hours to 29 hours, from 0.5 hours to 30 hours, from 0.5 hours
to 31 hours, from
0.5 hours to 32 hours, from 0.5 hours to 33 hours, from 0.5 hours to 34 hours,
from 0.5 hours to
35 hours, from 0.5 hours to 36 hours, from 1 hour to 1.5 hours, from 1 hour to
2 hours, from 1
hour to 2.5 hours, from 1 hour to 3 hours, from 1 hour to 3.5 hours, from 1
hour to 4 hours, from
1 hour to 4.5 hours, from 1 hour to 5 hours, from 1 hour to 5.5 hours, from 1
hour to 6 hours,
from 1 hour to 6.5 hours, from 1 hour to 7 hours, from 1 hour to 7.5 hours,
from 1 hour to 8
hours, from 1 hour to 8.5 hours, from 1 hour to 9 hours, from 1 hour to 9.5
hours, from 1 hour to
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hours, from 1 hour to 10.5 hours, from 1 hour to 11 hours, from 1 hour to 11.5
hours, from 1
hour to 12 hours, from 1 hour to 12.5 hours, from 1 hour to 13 hours, from 1
hour to 13.5 hours,
from 1 hour to 14 hours, from 1 hour to 14.5 hours, from 1 hour to 15 hours,
from 1 hour to 15.5
hours, from 1 hour to 16 hours, from 1 hour to 16.5 hours, from 1 hour to 17
hours, from 1 hour
to 17.5 hours, from 1 hour to 18 hours, from 1 hour to 18.5 hours, from 1 hour
to 19 hours, from
1 hour to 19.5 hours, from 1 hour to 20 hours, from 1 hour to 20.5 hours, from
1 hour to 21
hours, from 1 hour to 21.5 hours, from 1 hour to 22 hours, from 1 hour to 22.5
hours, from 1
hour to 23 hours, from 1 hour to 23.5 hours, from 1 hour to 24 hours, from 1
hours to 25 hours,
from 1 hours to 26 hours, from 1 hours to 27 hours, from 1 hours to 28 hours,
from 1 hours to 29
hours, from 1 hours to 30 hours, from 1 hours to 31 hours, from 1 hours to 32
hours, from 1
hours to 33 hours, from 1 hours to 34 hours, from 1 hours to 35 hours, from 1
hours to 36 hours,
from 1.5 hours to 2 hours, from 1.5 hours to 2.5 hours, from 1.5 hours to 3
hours, from 1.5 hours
to 3.5 hours, from 1.5 hours to 4 hours, from 1.5 hours to 4.5 hours, from 1.5
hours to 5 hours,
from 1.5 hours to 5.5 hours, from 1.5 hours to 6 hours, from 1.5 hours to 6.5
hours, from 1.5
hours to 7 hours, from 1.5 hours to 7.5 hours, from 1.5 hours to 8 hours, from
1.5 hours to 8.5
hours, from 1.5 hours to 9 hours, from 1.5 hours to 9.5 hours, from 1.5 hours
to 10 hours, from
1.5 hours to 10.5 hours, from 1.5 hours toll hours, from 1.5 hours to 11.5
hours, from 1.5 hours
to 12 hours, from 1.5 hours to 12.5 hours, from 1.5 hours to 13 hours, from
1.5 hours to 13.5
hours, from 1.5 hours to 14 hours, from 1.5 hours to 14.5 hours, from 1.5
hours to 15 hours, from
1.5 hours to 15.5 hours, from 1.5 hours to 16 hours, from 1.5 hours to 16.5
hours, from 1.5 hours
to 17 hours, from 1.5 hours to 17.5 hours, from 1.5 hours to 18 hours, from
1.5 hours to 18.5
hours, from 1.5 hours to 19 hours, from 1.5 hours to 19.5 hours, from 1.5
hours to 20 hours, from
1.5 hours to 20.5 hours, from 1.5 hours to 21 hours, from 1.5 hours to 21.5
hours, from 1.5 hours
to 22 hours, from 1.5 hours to 22.5 hours, from 1.5 hours to 23 hours, from
1.5 hours to 23.5
hours, from 1.5 hours to 24 hours, from 1.5 hours to 25 hours, from 1.5 hours
to 26 hours, from
1.5 hours to 27 hours, from 1.5 hours to 28 hours, from 1.5 hours to 29 hours,
from 1.5 hours to
30 hours, from 1.5 hours to 31 hours, from 1.5 hours to 32 hours, from 1.5
hours to 33 hours,
from 1.5 hours to 34 hours, from 1.5 hours to 35 hours, from 1.5 hours to 36
hours, from 2 hours
to 2.5 hours, from 2 hours to 3 hours, from 2 hours to 3.5 hours, from 2 hours
to 4 hours, from 2
hours to 4.5 hours, from 2 hours to 5 hours, from 2 hours to 5.5 hours, from 2
hours to 6 hours,
from 2 hours to 6.5 hours, from 2 hours to 7 hours, from 2 hours to 7.5 hours,
from 2 hours to 8

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hours, from 2 hours to 8.5 hours, from 2 hours to 9 hours, from 2 hours to 9.5
hours, from 2
hours to 10 hours, from 2 hours to 10.5 hours, from 2 hours to 11 hours, from
2 hours to 11.5
hours, from 2 hours to 12 hours, from 2 hours to 12.5 hours, from 2 hours to
13 hours, from 2
hours to 13.5 hours, from 2 hours to 14 hours, from 2 hours to 14.5 hours,
from 2 hours to 15
hours, from 2 hours to 15.5 hours, from 2 hours to 16 hours, from 2 hours to
16.5 hours, from 2
hours to 17 hours, from 2 hours to 17.5 hours, from 2 hours to 18 hours, from
2 hours to 18.5
hours, from 2 hours to 19 hours, from 2 hours to 19.5 hours, from 2 hours to
20 hours, from 2
hours to 20.5 hours, from 2 hours to 21 hours, from 2 hours to 21.5 hours,
from 2 hours to 22
hours, from 2 hours to 22.5 hours, from 2 hours to 23 hours, from 2 hours to
23.5 hours, from 2
hours to 24 hours, from 2 hours to 25 hours, from 2 hours to 26 hours, from 2
hours to 27 hours,
from 2 hours to 28 hours, from 2 hours to 29 hours, from 2 hours to 30 hours,
from 2 hours to 31
hours, from 2 hours to 32 hours, from 2 hours to 33 hours, from 2 hours to 34
hours, from 2
hours to 35 hours, from 2 hours to 36 hours, from 2.5 hours to 3 hours, from
2.5 hours to 3.5
hours, from 2.5 hours to 4 hours, from 2.5 hours to 4.5 hours, from 2.5 hours
to 5 hours, from 2.5
hours to 5.5 hours, from 2.5 hours to 6 hours, from 2.5 hours to 6.5 hours,
from 2.5 hours to 7
hours, from 2.5 hours to 7.5 hours, from 2.5 hours to 8 hours, from 2.5 hours
to 8.5 hours, from
2.5 hours to 9 hours, from 2.5 hours to 9.5 hours, from 2.5 hours to 10 hours,
from 2.5 hours to
10.5 hours, from 2.5 hours to 11 hours, from 2.5 hours to 11.5 hours, from 2.5
hours to 12 hours,
from 2.5 hours to 12.5 hours, from 2.5 hours to 13 hours, from 2.5 hours to
13.5 hours, from 2.5
hours to 14 hours, from 2.5 hours to 14.5 hours, from 2.5 hours to 15 hours,
from 2.5 hours to
15.5 hours, from 2.5 hours to 16 hours, from 2.5 hours to 16.5 hours, from 2.5
hours to 17 hours,
from 2.5 hours to 17.5 hours, from 2.5 hours to 18 hours, from 2.5 hours to
18.5 hours, from 2.5
hours to 19 hours, from 2.5 hours to 19.5 hours, from 2.5 hours to 20 hours,
from 2.5 hours to
20.5 hours, from 2.5 hours to 21 hours, from 2.5 hours to 21.5 hours, from 2.5
hours to 22 hours,
from 2.5 hours to 22.5 hours, from 2.5 hours to 23 hours, from 2.5 hours to
23.5 hours, from 2.5
hours to 24 hours, from 2.5 hours to 25 hours, from 2.5 hours to 26 hours,
from 2.5 hours to 27
hours, from 2.5 hours to 28 hours, from 2.5 hours to 29 hours, from 2.5 hours
to 30 hours, from 2
.5 hours to 31 hours, from 2.5 hours to 32 hours, from 2.5 hours to 33 hours,
from 2.5 hours to 34
hours, from 2.5 hours to 35 hours, from 2.5 hours to 36 hours, from 3 hours to
3.5 hours, from 3
hours to 4 hours, from 3 hours to 4.5 hours, from 3 hours to 5 hours, from 3
hours to 5.5 hours,
from 3 hours to 6 hours, from 3 hours to 6.5 hours, from 3 hours to 7 hours,
from 3 hours to 7.5
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hours, from 3 hours to 8 hours, from 3 hours to 8.5 hours, from 3 hours to 9
hours, from 3 hours
to 9.5 hours, from 3 hours to 10 hours, from 3 hours to 10.5 hours, from 3
hours to 11 hours,
from 3 hours to 11.5 hours, from 3 hours to 12 hours, from 3 hours to 12.5
hours, from 3 hours to
13 hours, from 3 hours to 13.5 hours, from 3 hours to 14 hours, from 3 hours
to 14.5 hours, from
3 hours to 15 hours, from 3 hours to 15.5 hours, from 3 hours to 16 hours,
from 3 hours to 16.5
hours, from 3 hours to 17 hours, from 3 hours to 17.5 hours, from 3 hours to
18 hours, from 3
hours to 18.5 hours, from 3 hours to 19 hours, from 3 hours to 19.5 hours,
from 3 hours to 20
hours, from 3 hours to 20.5 hours, from 3 hours to 21 hours, from 3 hours to
21.5 hours, from 3
hours to 22 hours, from 3 hours to 22.5 hours, from 3 hours to 23 hours, from
3 hours to 23.5
hours, from 3 hours to 24 hours, from 3 hours to 25 hours, from 3 hours to 26
hours, from 3
hours to 27 hours, from 3 hours to 28 hours, from 3 hours to 29 hours, from 3
hours to 30 hours,
from 3 hours to 31 hours, from 3 hours to 32 hours, from 3 hours to 33 hours,
from 3 hours to 34
hours, from 3 hours to 35 hours, from 3 hours to 36 hours, from 3.5 hours to 4
hours, from 3.5
hours to 4.5 hours, from 3.5 hours to 5 hours, from 3.5 hours to 5.5 hours,
from 3.5 hours to 6
hours, from 3.5 hours to 6.5 hours, from 3.5 hours to 7 hours, from 3.5 hours
to 7.5 hours, from
3.5 hours to 8 hours, from 3.5 hours to 8.5 hours, from 3.5 hours to 9 hours,
from 3.5 hours to 9.5
hours, from 3.5 hours to 10 hours, from 3.5 hours to 10.5 hours, from 3.5
hours to 11 hours, from
3.5 hours to 11.5 hours, from 3.5 hours to 12 hours, from 3.5 hours to 12.5
hours, from 3.5 hours
to 13 hours, from 3.5 hours to 13.5 hours, from 3.5 hours to 14 hours, from
3.5 hours to 14.5
hours, from 3.5 hours to 15 hours, from 3.5 hours to 15.5 hours, from 3.5
hours to 16 hours, from
3.5 hours to 16.5 hours, from 3.5 hours to 17 hours, from 3.5 hours to 17.5
hours, from 3.5 hours
to 18 hours, from 3.5 hours to 18.5 hours, from 3.5 hours to 19 hours, from
3.5 hours to 19.5
hours, from 3.5 hours to 20 hours, from 3.5 hours to 20.5 hours, from 3.5
hours to 21 hours, from
3.5 hours to 21.5 hours, from 3.5 hours to 22 hours, from 3.5 hours to 22.5
hours, from 3.5 hours
to 23 hours, from 3.5 hours to 23.5 hours, from 3.5 hours to 24 hours, from
3.5 hours to 25 hours,
from 3.5 hours to 26 hours, from 3.5 hours to 27 hours, from 3.5 hours to 28
hours, from 3.5
hours to 29 hours, from 3.5 hours to 30 hours, from 3.5 hours to 31 hours,
from 3.5 hours to 32
hours, from 3.5 hours to 33 hours, from 3.5 hours to 34 hours, from 3.5 hours
to 35 hours, from
3.5 hours to 36 hours, from 4 hours to 4.5 hours, from 4 hours to 5 hours,
from 4 hours to 5.5
hours, from 4 hours to 6 hours, from 4 hours to 6.5 hours, from 4 hours to 7
hours, from 4 hours
to 7.5 hours, from 4 hours to 8 hours, from 4 hours to 8.5 hours, from 4 hours
to 9 hours, from 4
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hours to 9.5 hours, from 4 hours to 10 hours, from 4 hours to 10.5 hours, from
4 hours to 11
hours, from 4 hours to 11.5 hours, from 4 hours to 12 hours, from 4 hours to
12.5 hours, from 4
hours to 13 hours, from 4 hours to 13.5 hours, from 4 hours to 14 hours, from
4 hours to 14.5
hours, from 4 hours to 15 hours, from 4 hours to 15.5 hours, from 4 hours to
16 hours, from 4
hours to 16.5 hours, from 4 hours to 17 hours, from 4 hours to 17.5 hours,
from 4 hours to 18
hours, from 4 hours to 18.5 hours, from 4 hours to 19 hours, from 4 hours to
19.5 hours, from 4
hours to 20 hours, from 4 hours to 20.5 hours, from 4 hours to 21 hours, from
4 hours to 21.5
hours, from 4 hours to 22 hours, from 4 hours to 22.5 hours, from 4 hours to
23 hours, from 4
hours to 23.5 hours, from 4 hours to 24 hours, from 4 hours to 25 hours, from
4 hours to 26
hours, from 4 hours to 27 hours, from 4 hours to 28 hours, from 4 hours to 29
hours, from 4
hours to 30 hours, from 4 hours to 31 hours, from 4 hours to 32 hours, from 4
hours to 33 hours,
from 4 hours to 34 hours, from 4 hours to 35 hours, from 4 hours to 36 hours,
from 4.5 hours to 5
hours, from 4.5 hours to 5.5 hours, from 4.5 hours to 6 hours, from 4.5 hours
to 6.5 hours, from
4.5 hours to 7 hours, from 4.5 hours to 7.5 hours, from 4.5 hours to 8 hours,
from 4.5 hours to 8.5
hours, from 4.5 hours to 9 hours, from 4.5 hours to 9.5 hours, from 4.5 hours
to 10 hours, from
4.5 hours to 10.5 hours, from 4.5 hours to 11 hours, from 4.5 hours to 11.5
hours, from 4.5 hours
to 12 hours, from 4.5 hours to 12.5 hours, from 4.5 hours to 13 hours, from
4.5 hours to 13.5
hours, from 4.5 hours to 14 hours, from 4.5 hours to 14.5 hours, from 4.5
hours to 15 hours, from
4.5 hours to 15.5 hours, from 4.5 hours to 16 hours, from 4.5 hours to 16.5
hours, from 4.5 hours
to 17 hours, from 4.5 hours to 17.5 hours, from 4.5 hours to 18 hours, from
4.5 hours to 18.5
hours, from 4.5 hours to 19 hours, from 4.5 hours to 19.5 hours, from 4.5
hours to 20 hours, from
4.5 hours to 20.5 hours, from 4.5 hours to 21 hours, from 4.5 hours to 21.5
hours, from 4.5 hours
to 22 hours, from 4.5 hours to 22.5 hours, from 4.5 hours to 23 hours, from
4.5 hours to 23.5
hours, from 4.5 hours to 24 hours, from 4.5 hours to 25 hours, from 4.5 hours
to 26 hours, from
4.5 hours to 27 hours, from 4.5 hours to 28 hours, from 4.5 hours to 29 hours,
from 4.5 hours to
30 hours, from 4.5 hours to 31 hours, from 4.5 hours to 32 hours, from 4.5
hours to 33 hours,
from 4.5 hours to 34 hours, from 4.5 hours to 35 hours, from 4.5 hours to 36
hours, from 5 hours
to 5.5 hours, from 5 hours to 6 hours, from 5 hours to 6.5 hours, from 5 hours
to 7 hours, from 5
hours to 7.5 hours, from 5 hours to 8 hours, from 5 hours to 8.5 hours, from 5
hours to 9 hours,
from 5 hours to 9.5 hours, from 5 hours to 10 hours, from 5 hours to 10.5
hours, from 5 hours to
11 hours, from 5 hours to 11.5 hours, from 5 hours to 12 hours, from 5 hours
to 12.5 hours, from
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hours to 13 hours, from 5 hours to 13.5 hours, from 5 hours to 14 hours, from
5 hours to 14.5
hours, from 5 hours to 15 hours, from 5 hours to 15.5 hours, from 5 hours to
16 hours, from 5
hours to 16.5 hours, from 5 hours to 17 hours, from 5 hours to 17.5 hours,
from 5 hours to 18
hours, from 5 hours to 18.5 hours, from 5 hours to 19 hours, from 5 hours to
19.5 hours, from 5
hours to 20 hours, from 5 hours to 20.5 hours, from 5 hours to 21 hours, from
5 hours to 21.5
hours, from 5 hours to 22 hours, from 5 hours to 22.5 hours, from 5 hours to
23 hours, from 5
hours to 23.5 hours, from 5 hours to 24 hours, from 5 hours to 25 hours, from
5 hours to 26
hours, from 5 hours to 27 hours, from 5 hours to 28 hours, from 5 hours to 29
hours, from 5
hours to 30 hours, from 5 hours to 31 hours, from 5 hours to 32 hours, from 5
hours to 33 hours,
from 5 hours to 34 hours, from 5 hours to 35 hours, from 5 hours to 36 hours,
from 5.5 hours to 6
hours, from 5.5 hours to 6.5 hours, from 5.5 hours to 7 hours, from 5.5 hours
to 7.5 hours, from
5.5 hours to 8 hours, from 5.5 hours to 8.5 hours, from 5.5 hours to 9 hours,
from 5.5 hours to 9.5
hours, from 5.5 hours to 10 hours, from 5.5 hours to 10.5 hours, from 5.5
hours to 11 hours, from
5.5 hours to 11.5 hours, from 5.5 hours to 12 hours, from 5.5 hours to 12.5
hours, from 5.5 hours
to 13 hours, from 5.5 hours to 13.5 hours, from 5.5 hours to 14 hours, from
5.5 hours to 14.5
hours, from 5.5 hours to 15 hours, from 5.5 hours to 15.5 hours, from 5.5
hours to 16 hours, from
5.5 hours to 16.5 hours, from 5.5 hours to 17 hours, from 5.5 hours to 17.5
hours, from 5.5 hours
to 18 hours, from 5.5 hours to 18.5 hours, from 5.5 hours to 19 hours, from
5.5 hours to 19.5
hours, from 5.5 hours to 20 hours, from 5.5 hours to 20.5 hours, from 5.5
hours to 21 hours, from
5.5 hours to 21.5 hours, from 5.5 hours to 22 hours, from 5.5 hours to 22.5
hours, from 5.5 hours
to 23 hours, from 5.5 hours to 23.5 hours, from 5.5 hours to 24 hours, from
5.5 hours to 25 hours,
from 5.5 hours to 26 hours, from 5.5 hours to 27 hours, from 5.5 hours to 28
hours, from 5.5
hours to 29 hours, from 5.5 hours to 30 hours, from 5.5 hours to 31 hours,
from 5.5 hours to 32
hours, from 5.5 hours to 33 hours, from 5.5 hours to 34 hours, from 5.5 hours
to 35 hours, from
5.5 hours to 36 hours, from 6 hours to 6.5 hours, from 6 hours to 7 hours,
from 6 hours to 7.5
hours, from 6 hours to 8 hours, from 6 hours to 8.5 hours, from 6 hours to 9
hours, from 6 hours
to 9.5 hours, from 6 hours to 10 hours, from 6 hours to 10.5 hours, from 6
hours to 11 hours,
from 6 hours to 11.5 hours, from 6 hours to 12 hours, from 6 hours to 12.5
hours, from 6 hours to
13 hours, from 6 hours to 13.5 hours, from 6 hours to 14 hours, from 6 hours
to 14.5 hours, from
6 hours to 15 hours, from 6 hours to 15.5 hours, from 6 hours to 16 hours,
from 6 hours to 16.5
hours, from 6 hours to 17 hours, from 6 hours to 17.5 hours, from 6 hours to
18 hours, from 6
24

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hours to 18.5 hours, from 6 hours to 19 hours, from 6 hours to 19.5 hours,
from 6 hours to 20
hours, from 6 hours to 20.5 hours, from 6 hours to 21 hours, from 6 hours to
21.5 hours, from 6
hours to 22 hours, from 6 hours to 22.5 hours, from 6 hours to 23 hours, from
6 hours to 23.5
hours, from 6 hours to 24 hours, from 6 hours to 25 hours, from 6 hours to 26
hours, from 6
hours to 27 hours, from 6 hours to 28 hours, from 6 hours to 29 hours, from 6
hours to 30 hours,
from 6 hours to 31 hours, from 6 hours to 32 hours, from 6 hours to 33 hours,
from 6 hours to 34
hours, from 6 hours to 35 hours, from 6 hours to 36 hours, from 6.5 hours to 7
hours, from 6.5
hours to 7.5 hours, from 6.5 hours to 8 hours, from 6.5 hours to 8.5 hours,
from 6.5 hours to 9
hours, from 6.5 hours to 9.5 hours, from 6.5 hours to 10 hours, from 6.5 hours
to 10.5 hours,
from 6.5 hours to 11 hours, from 6.5 hours to 11.5 hours, from 6.5 hours to 12
hours, from 6.5
hours to 12.5 hours, from 6.5 hours to 13 hours, from 6.5 hours to 13.5 hours,
from 6.5 hours to
14 hours, from 6.5 hours to 14.5 hours, from 6.5 hours to 15 hours, from 6.5
hours to 15.5 hours,
from 6.5 hours to 16 hours, from 6.5 hours to 16.5 hours, from 6.5 hours to 17
hours, from 6.5
hours to 17.5 hours, from 6.5 hours to 18 hours, from 6.5 hours to 18.5 hours,
from 6.5 hours to
19 hours, from 6.5 hours to 19.5 hours, from 6.5 hours to 20 hours, from 6.5
hours to 20.5 hours,
from 6.5 hours to 21 hours, from 6.5 hours to 21.5 hours, from 6.5 hours to 22
hours, from 6.5
hours to 22.5 hours, from 6.5 hours to 23 hours, from 6.5 hours to 23.5 hours,
from 6.5 hours to
24 hours, from 6.5 hours to 25 hours, from 6.5 hours to 26 hours, from 6.5
hours to 27 hours,
from 6.5 hours to 28 hours, from 6.5 hours to 29 hours, from 6.5 hours to 30
hours, from 6.5
hours to 31 hours, from 6.5 hours to 32 hours, from 6.5 hours to 33 hours,
from 6.5 hours to 34
hours, from 6.5 hours to 35 hours, from 6.5 hours to 36 hours, from 7 hours to
7.5 hours, from 7
hours to 8 hours, from 7 hours to 8.5 hours, from 7 hours to 9 hours, from 7
hours to 9.5 hours,
from 7 hours to 10 hours, from 7 hours to 10.5 hours, from 7 hours to 11
hours, from 7 hours to
11.5 hours, from 7 hours to 12 hours, from 7 hours to 12.5 hours, from 7 hours
to 13 hours, from
7 hours to 13.5 hours, from 7 hours to 14 hours, from 7 hours to 14.5 hours,
from 7 hours to 15
hours, from 7 hours to 15.5 hours, from 7 hours to 16 hours, from 7 hours to
16.5 hours, from 7
hours to 17 hours, from 7 hours to 17.5 hours, from 7 hours to 18 hours, from
7 hours to 18.5
hours, from 7 hours to 19 hours, from 7 hours to 19.5 hours, from 7 hours to
20 hours, from 7
hours to 20.5 hours, from 7 hours to 21 hours, from 7 hours to 21.5 hours,
from 7 hours to 22
hours, from 7 hours to 22.5 hours, from 7 hours to 23 hours, from 7 hours to
23.5 hours, from 7
hours to 24 hours, from 7 hours to 25 hours, from 7 hours to 26 hours, from 7
hours to 27 hours,

CA 03164133 2022-06-08
WO 2021/150610 PCT/US2021/014183
from 7 hours to 28 hours, from 7 hours to 29 hours, from 7 hours to 30 hours,
from 7 hours to 31
hours, from 7 hours to 32 hours, from 7 hours to 33 hours, from 7 hours to 34
hours, from 7
hours to 35 hours, from 7 hours to 36 hours, from 7.5 hours to 8 hours, from
7.5 hours to 8.5
hours, from 7.5 hours to 9 hours, from 7.5 hours to 9.5 hours, from 7.5 hours
to 10 hours, from
7.5 hours to 10.5 hours, from 7.5 hours toll hours, from 7.5 hours to 11.5
hours, from 7.5 hours
to 12 hours, from 7.5 hours to 12.5 hours, from 7.5 hours to 13 hours, from
7.5 hours to 13.5
hours, from 7.5 hours to 14 hours, from 7.5 hours to 14.5 hours, from 7.5
hours to 15 hours, from
7.5 hours to 15.5 hours, from 7.5 hours to 16 hours, from 7.5 hours to 16.5
hours, from 7.5 hours
to 17 hours, from 7.5 hours to 17.5 hours, from 7.5 hours to 18 hours, from
7.5 hours to 18.5
hours, from 7.5 hours to 19 hours, from 7.5 hours to 19.5 hours, from 7.5
hours to 20 hours, from
7.5 hours to 20.5 hours, from 7.5 hours to 21 hours, from 7.5 hours to 21.5
hours, from 7.5 hours
to 22 hours, from 7.5 hours to 22.5 hours, from 7.5 hours to 23 hours, from
7.5 hours to 23.5
hours, from 7.5 hours to 24 hours, from 7.5 hours to 25 hours, from 7.5 hours
to 26 hours, from
7.5 hours to 27 hours, from 7.5 hours to 28 hours, from 7.5 hours to 29 hours,
from 7.5 hours to
30 hours, from 7.5 hours to 31 hours, from 7.5 hours to 32 hours, from 7.5
hours to 33 hours,
from 7.5 hours to 34 hours, from 7.5 hours to 35 hours, from 7.5 hours to 36
hours, from 8 hours
to 8.5 hours, from 8 hours to 9 hours, from 8 hours to 9.5 hours, from 8 hours
to 10 hours, from 8
hours to 10.5 hours, from 8 hours to 11 hours, from 8 hours to 11.5 hours,
from 8 hours to 12
hours, from 8 hours to 12.5 hours, from 8 hours to 13 hours, from 8 hours to
13.5 hours, from 8
hours to 14 hours, from 8 hours to 14.5 hours, from 8 hours to 15 hours, from
8 hours to 15.5
hours, from 8 hours to 16 hours, from 8 hours to 16.5 hours, from 8 hours to
17 hours, from 8
hours to 17.5 hours, from 8 hours to 18 hours, from 8 hours to 18.5 hours,
from 8 hours to 19
hours, from 8 hours to 19.5 hours, from 8 hours to 20 hours, from 8 hours to
20.5 hours, from 8
hours to 21 hours, from 8 hours to 21.5 hours, from 8 hours to 22 hours, from
8 hours to 22.5
hours, from 8 hours to 23 hours, from 8 hours to 23.5 hours, from 8 hours to
24 hours, from 8
hours to 25 hours, from 8 hours to 26 hours, from 8 hours to 27 hours, from 8
hours to 28 hours,
from 8 hours to 29 hours, from 8 hours to 30 hours, from 8 hours to 31 hours,
from 8 hours to 32
hours, from 8 hours to 33 hours, from 8 hours to 34 hours, from 8 hours to 35
hours, from 8
hours to 36 hours, from 8.5 hours to 9 hours, from 8.5 hours to 9.5 hours,
from 8.5 hours to 10
hours, from 8.5 hours to 10.5 hours, from 8.5 hours to 11 hours, from 8.5
hours to 11.5 hours,
from 8.5 hours to 12 hours, from 8.5 hours to 12.5 hours, from 8.5 hours to 13
hours, from 8.5
26

CA 03164133 2022-06-08
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hours to 13.5 hours, from 8.5 hours to 14 hours, from 8.5 hours to 14.5 hours,
from 8.5 hours to
15 hours, from 8.5 hours to 15.5 hours, from 8.5 hours to 16 hours, from 8.5
hours to 16.5 hours,
from 8.5 hours to 17 hours, from 8.5 hours to 17.5 hours, from 8.5 hours to 18
hours, from 8.5
hours to 18.5 hours, from 8.5 hours to 19 hours, from 8.5 hours to 19.5 hours,
from 8.5 hours to
20 hours, from 8.5 hours to 20.5 hours, from 8.5 hours to 21 hours, from 8.5
hours to 21.5 hours,
from 8.5 hours to 22 hours, from 8.5 hours to 22.5 hours, from 8.5 hours to 23
hours, from 8.5
hours to 23.5 hours, from 8.5 hours to 24 hours, from 8.5 hours to 25 hours,
from 8.5 hours to 26
hours, from 8.5 hours to 27 hours, from 8.5 hours to 28 hours, from 8.5 hours
to 29 hours, from
8.5 hours to 30 hours, from 8.5 hours to 31 hours, from 8.5 hours to 32 hours,
from 8.5 hours to
33 hours, from 8.5 hours to 34 hours, from 8.5 hours to 35 hours, from 8.5
hours to 36 hours,
from 9 hours to 9.5 hours, from 9 hours to 10 hours, from 9 hours to 10.5
hours, from 9 hours to
11 hours, from 9 hours to 11.5 hours, from 9 hours to 12 hours, from 9 hours
to 12.5 hours, from
9 hours to 13 hours, from 9 hours to 13.5 hours, from 9 hours to 14 hours,
from 9 hours to 14.5
hours, from 9 hours to 15 hours, from 9 hours to 15.5 hours, from 9 hours to
16 hours, from 9
hours to 16.5 hours, from 9 hours to 17 hours, from 9 hours to 17.5 hours,
from 9 hours to 18
hours, from 9 hours to 18.5 hours, from 9 hours to 19 hours, from 9 hours to
19.5 hours, from 9
hours to 20 hours, from 9 hours to 20.5 hours, from 9 hours to 21 hours, from
9 hours to 21.5
hours, from 9 hours to 22 hours, from 9 hours to 22.5 hours, from 9 hours to
23 hours, from 9
hours to 23.5 hours, from 9 hours to 24 hours, from 9 hours to 25 hours, from
9 hours to 26
hours, from 9 hours to 27 hours, from 9 hours to 28 hours, from 9 hours to 29
hours, from 9
hours to 30 hours, from 9 hours to 31 hours, from 9 hours to 32 hours, from 9
hours to 33 hours,
from 9 hours to 34 hours, from 9 hours to 35 hours, from 9 hours to 36 hours,
from 9.5 hours to
hours, from 9.5 hours to 10.5 hours, from 9.5 hours to 11 hours, from 9.5
hours to 11.5 hours,
from 9.5 hours to 12 hours, from 9.5 hours to 12.5 hours, from 9.5 hours to 13
hours, from 9.5
hours to 13.5 hours, from 9.5 hours to 14 hours, from 9.5 hours to 14.5 hours,
from 9.5 hours to
hours, from 9.5 hours to 15.5 hours, from 9.5 hours to 16 hours, from 9.5
hours to 16.5 hours,
from 9.5 hours to 17 hours, from 9.5 hours to 17.5 hours, from 9.5 hours to 18
hours, from 9.5
hours to 18.5 hours, from 9.5 hours to 19 hours, from 9.5 hours to 19.5 hours,
from 9.5 hours to
hours, from 9.5 hours to 20.5 hours, from 9.5 hours to 21 hours, from 9.5
hours to 21.5 hours,
from 9.5 hours to 22 hours, from 9.5 hours to 22.5 hours, from 9.5 hours to 23
hours, from 9.5
hours to 23.5 hours, from 9.5 hours to 24 hours, from 9.5 hours to 25 hours,
from 9.5 hours to 26
27

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hours, from 9.5 hours to 27 hours, from 9.5 hours to 28 hours, from 9.5 hours
to 29 hours, from
9.5 hours to 30 hours, from 9.5 hours to 31 hours, from 9.5 hours to 32 hours,
from 9.5 hours to
33 hours, from 9.5 hours to 34 hours, from 9.5 hours to 35 hours, from 9.5
hours to 36 hours,
from 10 hours to 10.5 hours, from 10 hours to 11 hours, from 10 hours to 11.5
hours, from 10
hours to 12 hours, from 10 hours to 12.5 hours, from 10 hours to 13 hours,
from 10 hours to 13.5
hours, from 10 hours to 14 hours, from 10 hours to 14.5 hours, from 10 hours
to 15 hours, from
hours to 15.5 hours, from 10 hours to 16 hours, from 10 hours to 16.5 hours,
from 10 hours to
17 hours, from 10 hours to 17.5 hours, from 10 hours to 18 hours, from 10
hours to 18.5 hours,
from 10 hours to 19 hours, from 10 hours to 19.5 hours, from 10 hours to 20
hours, from 10
hours to 20.5 hours, from 10 hours to 21 hours, from 10 hours to 21.5 hours,
from 10 hours to 22
hours, from 10 hours to 22.5 hours, from 10 hours to 23 hours, from 10 hours
to 23.5 hours, from
10 hours to 24 hours, from 10 hours to 25 hours, from 10 hours to 26 hours,
from 10 hours to 27
hours, from 10 hours to 28 hours, from 10 hours to 29 hours, from 10 hours to
30 hours, from 10
hours to 31 hours, from 10 hours to 32 hours, from 10 hours to 33 hours, from
10 hours to 34
hours, from 10 hours to 35 hours, from 10 hours to 36 hours, from 10.5 hours
to 11 hours, from
10.5 hours to 11.5 hours, from 10.5 hours to 12 hours, from 10.5 hours to 12.5
hours, from 10.5
hours to 13 hours, from 10.5 hours to 13.5 hours, from 10.5 hours to 14 hours,
from 10.5 hours to
14.5 hours, from 10.5 hours to 15 hours, from 10.5 hours to 15.5 hours, from
10.5 hours to 16
hours, from 10.5 hours to 16.5 hours, from 10.5 hours to 17 hours, from 10.5
hours to 17.5 hours,
from 10.5 hours to 18 hours, from 10.5 hours to 18.5 hours, from 10.5 hours to
19 hours, from
10.5 hours to 19.5 hours, from 10.5 hours to 20 hours, from 10.5 hours to 20.5
hours, from 10.5
hours to 21 hours, from 10.5 hours to 21.5 hours, from 10.5 hours to 22 hours,
from 10.5 hours to
22.5 hours, from 10.5 hours to 23 hours, from 10.5 hours to 23.5 hours, from
10.5 hours to 24
hours, from 10.5 hours to 25 hours, from 10.5 hours to 26 hours, from 10.5
hours to 27 hours,
from 10.5 hours to 28 hours, from 10.5 hours to 29 hours, from 10.5 hours to
30 hours, from 10.5
hours to 31 hours, from 10.5 hours to 32 hours, from 10.5 hours to 33 hours,
from 10.5 hours to
34 hours, from 10.5 hours to 35 hours, from 10.5 hours to 36 hours, from 11
hours to 11.5 hours,
from 11 hours to 12 hours, from 11 hours to 12.5 hours, from 11 hours to 13
hours, from 11
hours to 13.5 hours, from 11 hours to 14 hours, from 11 hours to 14.5 hours,
from 11 hours to 15
hours, from 11 hours to 15.5 hours, from 11 hours to 16 hours, from 11 hours
to 16.5 hours, from
11 hours to 17 hours, from 11 hours to 17.5 hours, from 11 hours to 18 hours,
from 11 hours to
28

CA 03164133 2022-06-08
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18.5 hours, from 11 hours to 19 hours, from 11 hours to 19.5 hours, from 11
hours to 20 hours,
from 11 hours to 20.5 hours, from 11 hours to 21 hours, from 11 hours to 21.5
hours, from 11
hours to 22 hours, from 11 hours to 22.5 hours, from 11 hours to 23 hours,
from 11 hours to 23.5
hours, from 11 hours to 24 hours, from 11 hours to 25 hours, from 11 hours to
26 hours, from 11
hours to 27 hours, from 11 hours to 28 hours, from 11 hours to 29 hours, from
11 hours to 30
hours, from 11 hours to 31 hours, from 11 hours to 32 hours, from 11 hours to
33 hours, from 11
hours to 34 hours, from 11 hours to 35 hours, from 11 hours to 36 hours, from
11.5 hours to 12
hours, from 11.5 hours to 12.5 hours, from 11.5 hours to 13 hours, from 11.5
hours to 13.5 hours,
from 11.5 hours to 14 hours, from 11.5 hours to 14.5 hours, from 11.5 hours to
15 hours, from
11.5 hours to 15.5 hours, from 11.5 hours to 16 hours, from 11.5 hours to 16.5
hours, from 11.5
hours to 17 hours, from 11.5 hours to 17.5 hours, from 11.5 hours to 18 hours,
from 11.5 hours to
18.5 hours, from 11.5 hours to 19 hours, from 11.5 hours to 19.5 hours, from
11.5 hours to 20
hours, from 11.5 hours to 20.5 hours, from 11.5 hours to 21 hours, from 11.5
hours to 21.5 hours,
from 11.5 hours to 22 hours, from 11.5 hours to 22.5 hours, from 11.5 hours to
23 hours, from
11.5 hours to 23.5 hours, from 11.5 hours to 24 hours, from 11.5 hours to 25
hours, from 11.5
hours to 26 hours, from 11.5 hours to 27 hours, from 11.5 hours to 28 hours,
from 11.5 hours to
29 hours, from 11.5 hours to 30 hours, from 11.5 hours to 31 hours, from 11.5
hours to 32 hours,
from 11.5 hours to 33 hours, from 11.5 hours to 34 hours, from 11.5 hours to
35 hours, from 11.5
hours to 36 hours, from 12 hours to 12.5 hours, from 12 hours to 13 hours,
from 12 hours to 13.5
hours, from 12 hours to 14 hours, from 12 hours to 14.5 hours, from 12 hours
to 15 hours, from
12 hours to 15.5 hours, from 12 hours to 16 hours, from 12 hours to 16.5
hours, from 12 hours to
17 hours, from 12 hours to 17.5 hours, from 12 hours to 18 hours, from 12
hours to 18.5 hours,
from 12 hours to 19 hours, from 12 hours to 19.5 hours, from 12 hours to 20
hours, from 12
hours to 20.5 hours, from 12 hours to 21 hours, from 12 hours to 21.5 hours,
from 12 hours to 22
hours, from 12 hours to 22.5 hours, from 12 hours to 23 hours, from 12 hours
to 23.5 hours, from
12 hours to 24 hours, from 12 hours to 25 hours, from 12 hours to 26 hours,
from 12 hours to 27
hours, from 12 hours to 28 hours, from 12 hours to 29 hours, from 12 hours to
30 hours, from 12
hours to 31 hours, from 12 hours to 32 hours, from 12 hours to 33 hours, from
12 hours to 34
hours, from 12 hours to 35 hours, from 12 hours to 36 hours, from 12.5 hours
to 13 hours, from
12.5 hours to 13.5 hours, from 12.5 hours to 14 hours, from 12.5 hours to 14.5
hours, from 12.5
hours to 15 hours, from 12.5 hours to 15.5 hours, from 12.5 hours to 16 hours,
from 12.5 hours to
29

CA 03164133 2022-06-08
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16.5 hours, from 12.5 hours to 17 hours, from 12.5 hours to 17.5 hours, from
12.5 hours to 18
hours, from 12.5 hours to 18.5 hours, from 12.5 hours to 19 hours, from 12.5
hours to 19.5 hours,
from 12.5 hours to 20 hours, from 12.5 hours to 20.5 hours, from 12.5 hours to
21 hours, from
12.5 hours to 21.5 hours, from 12.5 hours to 22 hours, from 12.5 hours to 22.5
hours, from 12.5
hours to 23 hours, from 12.5 hours to 23.5 hours, from 12.5 hours to 24 hours,
from 12.5 hours to
25 hours, from 12.5 hours to 26 hours, from 12.5 hours to 27 hours, from 12.5
hours to 28 hours,
from 12.5 hours to 29 hours, from 12.5 hours to 30 hours, from 12.5 hours to
31 hours, from 12.5
hours to 32 hours, from 12.5 hours to 33 hours, from 12.5 hours to 34 hours,
from 12.5 hours to
35 hours, from 12.5 hours to 36 hours, from 13 hours to 13.5 hours, from 13
hours to 14 hours,
from 13 hours to 14.5 hours, from 13 hours to 15 hours, from 13 hours to 15.5
hours, from 13
hours to 16 hours, from 13 hours to 16.5 hours, from 13 hours to 17 hours,
from 13 hours to 17.5
hours, from 13 hours to 18 hours, from 13 hours to 18.5 hours, from 13 hours
to 19 hours, from
13 hours to 19.5 hours, from 13 hours to 20 hours, from 13 hours to 20.5
hours, from 13 hours to
21 hours, from 13 hours to 21.5 hours, from 13 hours to 22 hours, from 13
hours to 22.5 hours,
from 13 hours to 23 hours, from 13 hours to 23.5 hours, from 13 hours to 24
hours, from 13
hours to 25 hours, from 13 hours to 26 hours, from 13 hours to 27 hours, from
13 hours to 28
hours, from 13 hours to 29 hours, from 13 hours to 30 hours, from 13 hours to
31 hours, from 13
hours to 32 hours, from 13 hours to 33 hours, from 13 hours to 34 hours, from
13 hours to 35
hours, from 13 hours to 36 hours, from 13.5 hours to 14 hours, from 13.5 hours
to 14.5 hours,
from 13.5 hours to 15 hours, from 13.5 hours to 15.5 hours, from 13.5 hours to
16 hours, from
13.5 hours to 16.5 hours, from 13.5 hours to 17 hours, from 13.5 hours to 17.5
hours, from 13.5
hours to 18 hours, from 13.5 hours to 18.5 hours, from 13.5 hours to 19 hours,
from 13.5 hours to
19.5 hours, from 13.5 hours to 20 hours, from 13.5 hours to 20.5 hours, from
13.5 hours to 21
hours, from 13.5 hours to 21.5 hours, from 13.5 hours to 22 hours, from 13.5
hours to 22.5 hours,
from 13.5 hours to 23 hours, from 13.5 hours to 23.5 hours, from 13.5 hours to
24 hours, from
13.5 hours to 25 hours, from 13.5 hours to 26 hours, from 13.5 hours to 27
hours, from 13.5
hours to 28 hours, from 13.5 hours to 29 hours, from 13.5 hours to 30 hours,
from 13.5 hours to
31 hours, from 13.5 hours to 32 hours, from 13.5 hours to 33 hours, from 13.5
hours to 34 hours,
from 13.5 hours to 35 hours, from 13.5 hours to 36 hours, from 14 hours to
14.5 hours, from 14
hours to 15 hours, from 14 hours to 15.5 hours, from 14 hours to 16 hours,
from 14 hours to 16.5
hours, from 14 hours to 17 hours, from 14 hours to 17.5 hours, from 14 hours
to 18 hours, from

CA 03164133 2022-06-08
WO 2021/150610 PCT/US2021/014183
14 hours to 18.5 hours, from 14 hours to 19 hours, from 14 hours to 19.5
hours, from 14 hours to
20 hours, from 14 hours to 20.5 hours, from 14 hours to 21 hours, from 14
hours to 21.5 hours,
from 14 hours to 22 hours, from 14 hours to 22.5 hours, from 14 hours to 23
hours, from 14
hours to 23.5 hours, from 14 hours to 24 hours, from 14 hours to 25 hours,
from 14 hours to 26
hours, from 14 hours to 27 hours, from 14 hours to 28 hours, from 14 hours to
29 hours, from 14
hours to 30 hours, from 14 hours to 31 hours, from 14 hours to 32 hours, from
14 hours to 33
hours, from 14 hours to 34 hours, from 14 hours to 35 hours, from 14 hours to
36 hours, from
14.5 hours to 15 hours, from 14.5 hours to 15.5 hours, from 14.5 hours to 16
hours, from 14.5
hours to 16.5 hours, from 14.5 hours to 17 hours, from 14.5 hours to 17.5
hours, from 14.5 hours
to 18 hours, from 14.5 hours to 18.5 hours, from 14.5 hours to 19 hours, from
14.5 hours to 19.5
hours, from 14.5 hours to 20 hours, from 14.5 hours to 20.5 hours, from 14.5
hours to 21 hours,
from 14.5 hours to 21.5 hours, from 14.5 hours to 22 hours, from 14.5 hours to
22.5 hours, from
14.5 hours to 23 hours, from 14.5 hours to 23.5 hours, from 14.5 hours to 24
hours, from 14.5
hours to 25 hours, from 14.5 hours to 26 hours, from 14.5 hours to 27 hours,
from 14.5 hours to
28 hours, from 14.5 hours to 29 hours, from 14.5 hours to 30 hours, from 14.5
hours to 31 hours,
from 14.5 hours to 32 hours, from 14.5 hours to 33 hours, from 14.5 hours to
34 hours, from 14.5
hours to 35 hours, from 14.5 hours to 36 hours, from 15 hours to 15.5 hours,
from 15 hours to 16
hours, from 15 hours to 16.5 hours, from 15 hours to 17 hours, from 15 hours
to 17.5 hours, from
15 hours to 18 hours, from 15 hours to 18.5 hours, from 15 hours to 19 hours,
from 15 hours to
19.5 hours, from 15 hours to 20 hours, from 15 hours to 20.5 hours, from 15
hours to 21 hours,
from 15 hours to 21.5 hours, from 15 hours to 22 hours, from 15 hours to 22.5
hours, from 15
hours to 23 hours, from 15 hours to 23.5 hours, from 15 hours to 24 hours,
from 15 hours to 25
hours, from 15 hours to 26 hours, from 15 hours to 27 hours, from 15 hours to
28 hours, from 15
hours to 29 hours, from 15 hours to 30 hours, from 15 hours to 31 hours, from
15 hours to 32
hours, from 15 hours to 33 hours, from 15 hours to 34 hours, from 15 hours to
35 hours, from 15
hours to 36 hours, from 15.5 hours to 16 hours, from 15.5 hours to 16.5 hours,
from 15.5 hours to
17 hours, from 15.5 hours to 17.5 hours, from 15.5 hours to 18 hours, from
15.5 hours to 18.5
hours, from 15.5 hours to 19 hours, from 15.5 hours to 19.5 hours, from 15.5
hours to 20 hours,
from 15.5 hours to 20.5 hours, from 15.5 hours to 21 hours, from 15.5 hours to
21.5 hours, from
15.5 hours to 22 hours, from 15.5 hours to 22.5 hours, from 15.5 hours to 23
hours, from 15.5
hours to 23.5 hours, from 15.5 hours to 24 hours, from 15.5 hours to 25 hours,
from 15.5 hours to
31

CA 03164133 2022-06-08
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26 hours, from 15.5 hours to 27 hours, from 15.5 hours to 28 hours, from 15.5
hours to 29 hours,
from 15.5 hours to 30 hours, from 15.5 hours to 31 hours, from 15.5 hours to
32 hours, from 15.5
hours to 33 hours, from 15.5 hours to 34 hours, from 15.5 hours to 35 hours,
from 15.5 hours to
36 hours, from 16 hours to 16.5 hours, from 16 hours to 17 hours, from 16
hours to 17.5 hours,
from 16 hours to 18 hours, from 16 hours to 18.5 hours, from 16 hours to 19
hours, from 16
hours to 19.5 hours, from 16 hours to 20 hours, from 16 hours to 20.5 hours,
from 16 hours to 21
hours, from 16 hours to 21.5 hours, from 16 hours to 22 hours, from 16 hours
to 22.5 hours, from
16 hours to 23 hours, from 16 hours to 23.5 hours, from 16 hours to 24 hours,
from 16 hours to
25 hours, from 16 hours to 26 hours, from 16 hours to 27 hours, from 16 hours
to 28 hours, from
16 hours to 29 hours, from 16 hours to 30 hours, from 16 hours to 31 hours,
from 16 hours to 32
hours, from 16 hours to 33 hours, from 16 hours to 34 hours, from 16 hours to
35 hours, from 16
hours to 36 hours, from 16.5 hours to 17 hours, from 16.5 hours to 17.5 hours,
from 16.5 hours to
18 hours, from 16.5 hours to 18.5 hours, from 16.5 hours to 19 hours, from
16.5 hours to 19.5
hours, from 16.5 hours to 20 hours, from 16.5 hours to 20.5 hours, from 16.5
hours to 21 hours,
from 16.5 hours to 21.5 hours, from 16.5 hours to 22 hours, from 16.5 hours to
22.5 hours, from
16.5 hours to 23 hours, from 16.5 hours to 23.5 hours, from 16.5 hours to 24
hours, from 16.5
hours to 25 hours, from 16.5 hours to 26 hours, from 16.5 hours to 27 hours,
from 16.5 hours to
28 hours, from 16.5 hours to 29 hours, from 16.5 hours to 30 hours, from 16.5
hours to 31 hours,
from 16.5 hours to 32 hours, from 16.5 hours to 33 hours, from 16.5 hours to
34 hours, from 16.5
hours to 35 hours, from 16.5 hours to 36 hours, from 17 hours to 17.5 hours,
from 17 hours to 18
hours, from 17 hours to 18.5 hours, from 17 hours to 19 hours, from 17 hours
to 19.5 hours, from
17 hours to 20 hours, from 17 hours to 20.5 hours, from 17 hours to 21 hours,
from 17 hours to
21.5 hours, from 17 hours to 22 hours, from 17 hours to 22.5 hours, from 17
hours to 23 hours,
from 17 hours to 23.5 hours, from 17 hours to 24 hours, from 17 hours to 25
hours, from 17
hours to 26 hours, from 17 hours to 27 hours, from 17 hours to 28 hours, from
17 hours to 29
hours, from 17 hours to 30 hours, from 17 hours to 31 hours, from 17 hours to
32 hours, from 17
hours to 33 hours, from 17 hours to 34 hours, from 17 hours to 35 hours, from
17 hours to 36
hours, from 17.5 hours to 18 hours, from 17.5 hours to 18.5 hours, from 17.5
hours to 19 hours,
from 17.5 hours to 19.5 hours, from 17.5 hours to 20 hours, from 17.5 hours to
20.5 hours, from
17.5 hours to 21 hours, from 17.5 hours to 21.5 hours, from 17.5 hours to 22
hours, from 17.5
hours to 22.5 hours, from 17.5 hours to 23 hours, from 17.5 hours to 23.5
hours, from 17.5 hours
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to 24 hours, from 17.5 hours to 25 hours, from 17.5 hours to 26 hours, from
17.5 hours to 27
hours, from 17.5 hours to 28 hours, from 17.5 hours to 29 hours, from 17.5
hours to 30 hours,
from 17.5 hours to 31 hours, from 17.5 hours to 32 hours, from 17.5 hours to
33 hours, from 17.5
hours to 34 hours, from 17.5 hours to 35 hours, from 17.5 hours to 36 hours,
from 18 hours to
18.5 hours, from 18 hours to 19 hours, from 18 hours to 19.5 hours, from 18
hours to 20 hours,
from 18 hours to 20.5 hours, from 18 hours to 21 hours, from 18 hours to 21.5
hours, from 18
hours to 22 hours, from 18 hours to 22.5 hours, from 18 hours to 23 hours,
from 18 hours to 23.5
hours, from 18 hours to 24 hours, from 18 hours to 25 hours, from 18 hours to
26 hours, from 18
hours to 27 hours, from 18 hours to 28 hours, from 18 hours to 29 hours, from
18 hours to 30
hours, from 18 hours to 31 hours, from 18 hours to 32 hours, from 18 hours to
33 hours, from 18
hours to 34 hours, from 18 hours to 35 hours, from 18 hours to 36 hours, from
18.5 hours to 19
hours, from 18.5 hours to 19.5 hours, from 18.5 hours to 20 hours, from 18.5
hours to 20.5 hours,
from 18.5 hours to 21 hours, from 18.5 hours to 21.5 hours, from 18.5 hours to
22 hours, from
18.5 hours to 22.5 hours, from 18.5 hours to 23 hours, from 18.5 hours to 23.5
hours, from 18.5
hours to 24 hours, from 18.5 hours to 25 hours, from 18.5 hours to 26 hours,
from 18.5 hours to
27 hours, from 18.5 hours to 28 hours, from 18.5 hours to 29 hours, from 18.5
hours to 30 hours,
from 18.5 hours to 31 hours, from 18.5 hours to 32 hours, from 18.5 hours to
33 hours, from 18.5
hours to 34 hours, from 18.5 hours to 35 hours, from 18.5 hours to 36 hours,
from 19 hours to
19.5 hours, from 19 hours to 20 hours, from 19 hours to 20.5 hours, from 19
hours to 21 hours,
from 19 hours to 21.5 hours, from 19 hours to 22 hours, from 19 hours to 22.5
hours, from 19
hours to 23 hours, from 19 hours to 23.5 hours, from 19 hours to 24 hours,
from 19 hours to 25
hours, from 19 hours to 26 hours, from 19 hours to 27 hours, from 19 hours to
28 hours, from 19
hours to 29 hours, from 19 hours to 30 hours, from 19 hours to 31 hours, from
19 hours to 32
hours, from 19 hours to 33 hours, from 19 hours to 34 hours, from 19 hours to
35 hours, from 19
hours to 36 hours, from 19.5 hours to 20 hours, from 19.5 hours to 20.5 hours,
from 19.5 hours to
21 hours, from 19.5 hours to 21.5 hours, from 19.5 hours to 22 hours, from
19.5 hours to 22.5
hours, from 19.5 hours to 23 hours, from 19.5 hours to 23.5 hours, from 19.5
hours to 24 hours,
from 19.5 hours to 25 hours, from 19.5 hours to 26 hours, from 19.5 hours to
27 hours, from 19.5
hours to 28 hours, from 19.5 hours to 29 hours, from 19.5 hours to 30 hours,
from 19.5 hours to
31 hours, from 19.5 hours to 32 hours, from 19.5 hours to 33 hours, from 19.5
hours to 34 hours,
from 19.5 hours to 35 hours, from 19.5 hours to 36 hours, from 20 hours to
20.5 hours, from 20
33

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hours to 21 hours, from 20 hours to 21.5 hours, from 20 hours to 22 hours,
from 20 hours to 22.5
hours, from 20 hours to 23 hours, from 20 hours to 23.5 hours, from 20 hours
to 24 hours, from
20 hours to 25 hours, from 20 hours to 26 hours, from 20 hours to 27 hours,
from 20 hours to 28
hours, from 20 hours to 29 hours, from 20 hours to 30 hours, from 20 hours to
31 hours, from 20
hours to 32 hours, from 20 hours to 33 hours, from 20 hours to 34 hours, from
20 hours to 35
hours, from 20 hours to 36 hours, from 20.5 hours to 21 hours, from 20.5 hours
to 21.5 hours,
from 20.5 hours to 22 hours, from 20.5 hours to 22.5 hours, from 20.5 hours to
23 hours, from
20.5 hours to 23.5 hours, from 20.5 hours to 24 hours, from 20.5 hours to 25
hours, from 20.5
hours to 26 hours, from 20.5 hours to 27 hours, from 20.5 hours to 28 hours,
from 20.5 hours to
29 hours, from 20.5 hours to 30 hours, from 20.5 hours to 31 hours, from 20.5
hours to 32 hours,
from 20.5 hours to 33 hours, from 20.5 hours to 34 hours, from 20.5 hours to
35 hours, from 20.5
hours to 36 hours, from 21 hours to 21.5 hours, from 21 hours to 22 hours,
from 21 hours to 22.5
hours, from 21 hours to 23 hours, from 21 hours to 23.5 hours, from 21 hours
to 24 hours, from
21 hours to 25 hours, from 21 hours to 26 hours, from 21 hours to 27 hours,
from 21 hours to 28
hours, from 21 hours to 29 hours, from 21 hours to 30 hours, from 21 hours to
31 hours, from 21
hours to 32 hours, from 21 hours to 33 hours, from 21 hours to 34 hours, from
21 hours to 35
hours, from 21 hours to 36 hours, from 21.5 hours to 22 hours, from 21.5 hours
to 22.5 hours,
from 21.5 hours to 23 hours, from 21.5 hours to 23.5 hours, from 21.5 hours to
24 hours, from
21.5 hours to 25 hours, from 21.5 hours to 26 hours, from 21.5 hours to 27
hours, from 21.5
hours to 28 hours, from 21.5 hours to 29 hours, from 21.5 hours to 30 hours,
from 21.5 hours to
31 hours, from 21.5 hours to 32 hours, from 21.5 hours to 33 hours, from 21.5
hours to 34 hours,
from 21.5 hours to 35 hours, from 21.5 hours to 36 hours, from 22 hours to
22.5 hours, from 22
hours to 23 hours, from 22 hours to 23.5 hours, from 22 hours to 24 hours,
from 22 hours to 25
hours, from 22 hours to 26 hours, from 22 hours to 27 hours, from 22 hours to
28 hours, from 22
hours to 29 hours, from 22 hours to 30 hours, from 22 hours to 31 hours, from
22 hours to 32
hours, from 22 hours to 33 hours, from 22 hours to 34 hours, from 22 hours to
35 hours, from 22
hours to 36 hours, from 22.5 hours to 23 hours, from 22.5 hours to 23.5 hours,
from 22.5 hours to
24 hours, from 22.5 hours to 25 hours, from 22.5 hours to 26 hours, from 22.5
hours to 27 hours,
from 22.5 hours to 28 hours, from 22.5 hours to 29 hours, from 22.5 hours to
30 hours, from 22.5
hours to 31 hours, from 22.5 hours to 32 hours, from 22.5 hours to 33 hours,
from 22.5 hours to
34 hours, from 22.5 hours to 35 hours, from 22.5 hours to 36 hours, from 23
hours to 23.5 hours,
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from 23 hours to 24 hours, from 23 hours to 25 hours, from 23 hours to 26
hours, from 23 hours
to 27 hours, from 23 hours to 28 hours, from 23 hours to 29 hours, from 23
hours to 30 hours,
from 23 hours to 31 hours, from 23 hours to 32 hours, from 23 hours to 33
hours, from 23 hours
to 34 hours, from 23 hours to 35 hours, from 23 hours to 36 hours, from 23.5
hours to 24 hours,
from 23.5 hours to 25 hours, from 23.5 hours to 26 hours, from 23.5 hours to
27 hours, from 23.5
hours to 28 hours, from 23.5 hours to 29 hours, from 23.5 hours to 30 hours,
from 23.5 hours to
31 hours, from 23.5 hours to 32 hours, from 23.5 hours to 33 hours, from 23.5
hours to 34 hours,
from 23.5 hours to 35 hours, from 23.5 hours to 36 hours, from 24 hours to 25
hours, from 24
hours to 26 hours, from 24 hours to 27 hours, from 24 hours to 28 hours, from
24 hours to 29
hours, from 24 hours to 30 hours, from 24 hours to 31 hours, from 24 hours to
32 hours, from 24
hours to 33 hours, from 24 hours to 34 hours, from 24 hours to 35 hours, from
24 hours to 36
hours, from 25 hours to 26 hours, from 25 hours to 27 hours, from 25 hours to
28 hours, from 25
hours to 29 hours, from 25 hours to 30 hours, from 25 hours to 31 hours, from
25 hours to 32
hours, from 25 hours to 33 hours, from 25 hours to 34 hours, from 25 hours to
35 hours, from 25
hours to 36 hours, from 26 hours to 27 hours, from 26 hours to 28 hours, from
26 hours to 29
hours, from 26 hours to 30 hours, from 26 hours to 31 hours, from 26 hours to
32 hours, from 26
hours to 33 hours, from 26 hours to 34 hours, from 26 hours to 35 hours, from
26 hours to 36
hours, from 27 hours to 28 hours, from 27 hours to 29 hours, from 27 hours to
30 hours, from 27
hours to 31 hours, from 27 hours to 32 hours, from 27 hours to 33 hours, from
27 hours to 34
hours, from 27 hours to 35 hours, from 27 hours to 36 hours, from 28 hours to
29 hours, from 28
hours to 30 hours, from 28 hours to 31 hours, from 28 hours to 32 hours, from
28 hours to 33
hours, from 28 hours to 34 hours, from 28 hours to 35 hours, from 28 hours to
36 hours, from 29
hours to 30 hours, from 29 hours to 31 hours, from 29 hours to 32 hours, from
29 hours to 33
hours, from 29 hours to 34 hours, from 29 hours to 35 hours, from 29 hours to
36 hours, from 30
hours to 31 hours, from 30 hours to 32 hours, from 30 hours to 33 hours, from
30 hours to 34
hours, from 30 hours to 35 hours, from 30 hours to 36 hours, from 31 hours to
32 hours, from 31
hours to 33 hours, from 31 hours to 34 hours, from 31 hours to 35 hours, from
31 hours to 36
hours, from 32 hours to 33 hours, from 32 hours to 34 hours, from 32 hours to
35 hours, from 32
hours to 36 hours, from 33 hours to 34 hours, from 33 hours to 35 hours, from
33 hours to 36
hours, from 34 hours to 35 hours, from 34 hours to 36 hours, or from 35 hours
to 36 hours.

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[0023] In some embodiments, during the soaking, a size of the 0-phase
intermetallic particles
decreases as compared to a size of the 0-phase intermetallic particles prior
to the soaking. In
some embodiments, during the soaking, a number density of the 0-phase
intermetallic particles in
the cast aluminum alloy product decreases as compared to a number density of
the 0-phase
intermetallic particles in the cast aluminum alloy product prior to the
soaking.
[0024] Methods of this aspect may optionally further comprise subjecting
the homogenized
aluminum alloy product to one or more rolling processes to produce a rolled
aluminum alloy
product. Optionally, the one or more rolling processes comprise at least one
of a hot rolling
process or a cold rolling process. Optionally, the hot rolling process may
comprise an exit
temperature of from 100 C to 500 C, such as from from 100 C to 150 C, from
100 C to 200
C, from 100 C to 250 C, from 100 C to 300 C, from 100 C to 350 C, from
100 C to 400
C, from 100 C to 450 C, from 150 C to 200 C, from 150 C to 250 C, from
150 C to 300
C, from 150 C to 350 C, from 150 C to 400 C, from 150 C to 450 C, from
150 C to 500
C, from 200 C to 250 C, from 200 C to 300 C, from 200 C to 350 C, from
200 C to 400
C, from 200 C to 450 C, from 200 C to 500 C, from 250 C to 300 C, from
250 C to 350
C, from 250 C to 400 C, from 250 C to 450 C, from 250 C to 500 C, from
300 C to 350
C, from 300 C to 400 C, from 300 C to 450 C, from 300 C to 500 C, from
350 C to 400
C, from 350 C to 450 C, from 350 C to 500 C, from 400 C to 450 C, from
400 C to 500
C, or from 450 C to 500 C. Optionally, the rolled aluminum alloy product
produced by the
hot rolling process has a thickness from 1 mm to 8 mm, such as from 1 mm to 2
mm, from 1 mm
to 3 mm, from 1 mm to 4 mm, from 1 mm to 5 mm, from 1 mm to 6 mm, from 1 mm to
7 mm,
from 2 mm to 3 mm, from 2 mm to 4 mm, from 2 mm to 5 mm, from 2 mm to 6 mm,
from 2 mm
to 7 mm, from 2 mm to 8 mm, from 3 mm to 4 mm, from 3 mm to 5 mm, from 3 mm to
6 mm,
from 3 mm to 7 mm, from 3 mm to 8 mm, from 4 mm to 5 mm, from 4 mm to 6 mm,
from 4 mm
to 7 mm, from 4 mm to 8 mm, from 5 mm to 6 mm, from 5 mm to 7 mm, from 5 mm to
8 mm,
from 6 mm to 7 mm, from 6 mm to 8 mm, or from 7 mm to 8 mm.
[0025] Optionally, the cold rolling process may comprise an exit
temperature of from 50 C
to 250 C, such as from 50 C to 100 C, from 50 C to 150 C, from 50 C to
200 C, from 100
C to 150 C, from 100 C to 200 C, from 100 C to 250 C, from 150 C to 200
C, from 150
C to 250 C, or from 200 C to 250 C. Optionally, the rolled aluminum alloy
product
produced by the cold rolling process has a thickness from 0.15 mm to 0.50 mm,
such as from
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0.15 mm to 0.20 mm, from 0.15 mm to 0.25 mmõ from 0.15 mm to 0.30 mm, from
0.15 mm to
0.35 mm, from 0.15 mm to 0.40 mm, from 0.15 mm to 0.45 mm, from 0.15 mm to
0.50 mm,
from 0.20 mm to 0.25 mm, from 0.20 mm to 0.30 mm, from 0.20 mm to 0.35 mm,
from 0.20 mm
to 0.40 mm, from 0.20 mm to 0.45 mm, from 0.20 mm to 0.50 mm, from 0.25 mm to
0.30 mm,
from 0.25 mm to 0.35 mm, from 0.25 mm to 0.40 mm, from 0.25 mm to 0.45 mm,
from 0.25 mm
to 0.50 mm, from 0.30 mm to 0.35 mm, from 0.30 mm to 0.40 mm, from 0.30 mm to
0.50 mm,
from 0.35 mm to 0.40 mm, from 0.35 mm to 0.45 mm, from 0.35 mm to 0.50 mm,
from 0.40 mm
to 0.45 mm, from 0.40 mm to 0.50 mm, or from 0.45 mm to 0.50 mm.
[0026] In another aspect, methods for improving formability of a metal
product are provided.
An example method of this aspect comprises providing a cast metal product
comprising a metal
composite, wherein the metal composite comprises iron, magnesium, manganese,
and silicon,
wherein a ratio of a silicon wt. % in the metal composite to an iron wt. % in
the metal composite
is from 0.5 to 1.0, and homogenizing the cast metal product to control an
inter-particle spacing of
the plurality of particles and to control a particle density of the plurality
of particles such to
achieve a ratio of a peak inter-particle spacing to a particle number density
from 0.0003/um to
0.0006/um. Optionally, the metal composite includes a plurality of particles
including a-phase
intermetallic particles comprising silicon and one or more of iron or
manganese and 0-phase
intermetallic particles comprising one or more of iron or manganese.
[0027] In some embodiments, the metal composite of the method described
includes an
inter-particle spacing is from 1 um to 25 um. In some embodiments, the metal
composite of the
method described includes the particle density is from 5 to 30,000 particles
per um2.
[0028] In some embodiments, the metal composite of the method described
includes the
particle density is from 50 to 1,000 particles per um2. In some embodiments,
the metal
composite of the method described includes the plurality of particles
comprising a particle
diameter from 1 um to 50 um. Optionally, the plurality of particles may have
diameters of from
500 nm to 50 um.
[0029] Various homogenizing conditions are useful with the methods
described herein. For
example, the homogenization temperature may be from 400 C to less than the
melting point of
aluminum (e.g., 660 C) or to less than the solidus point of the particular
alloy. For example, an
example time duration for the soaking may be from 0.1 hours to 48 hours.
Optionally, the
homogenization temperature is within 25 C of a solidus temperature of the
cast metal product.
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[0030] The source aluminum alloy(s) for the aluminum alloy products
prepared according to
the above described methods may correspond to the same series aluminum alloy
or a mixture of
different series aluminum alloys. Optionally, preparing the cast aluminum
alloy product
comprises preparing a molten 3xxx series aluminum alloy and casting the molten
3xxx series
aluminum alloy. Optionally, preparing the molten 3xxx series aluminum alloy
comprises
melting both a 3xxx series source aluminum alloy and a 5xxx series source
aluminum alloy.
Optionally, the 3xxx series source aluminum alloy and the 5xxx series source
aluminum alloy
are from a recycled source. In some embodiments, aluminum alloys including a
higher
percentage of silicon may be useful for achieving a target silicon to iron
ratio. For example,
preparing the molten aluminum alloy optionally further comprises melting a
4xxx series
aluminum alloy or a 6xxx series aluminum alloy along with a 3xxx series source
aluminum alloy
and a 5xxx series source aluminum alloy.
[0031] In some embodiments, multiple homogenization steps may be useful.
For example, a
secondary lower temperature homogenization after a first, higher temperature
and/or long
duration, homogenization may be useful for preparing an aluminum alloy
product, such as for
rolling or other processing. A multiple-step homogenization process may
include reducing a
temperature of the homogenized aluminum alloy product to a second
homogenization
temperature less than the first homogenization temperature; and soaking the
homogenized
aluminum alloy product at the second homogenization temperature for a second
time duration,
such as a second time duration that is shorter than the time duration of the
initial long-duration
soak. For example, the second time duration may be from 1 hour to 24 hours,
such as from 1
hour to 2 hours, from 1 hour to 3 hours, from 1 hour to 4 hours, from 1 hour
to 5 hours, from 1
hour to 6 hours, from 1 hour to 7 hours, from 1 hour to 8 hours, from 1 hour
to 9 hours, from 1
hour to 10 hours, from 1 hour to 11 hours, from 1 hour to 12 hours, from 1
hour to 13 hours,
from 1 hour to 14 hours, from 1 hour to 15 hours, from 1 hour to 16 hours,
from 1 hour to 17
hours, from 1 hour to 18 hours, from 1 hour to 19 hours, from 1 hour to 20
hours, from 1 hour to
21 hours, from 1 hour to 22 hours, from 1 hour to 23 hours, from 2 hours to 3
hours, from 2
hours to 4 hours, from 2 hours to 5 hours, from 2 hours to 6 hours, from 2
hours to 7 hours, from
2 hours to 8 hours, from 2 hours to 9 hours, from 2 hours to 10 hours, from 2
hours to 11 hours,
from 2 hours to 12 hours, from 2 hours to 13 hours, from 2 hours to 14 hours,
from 2 hours to 15
hours, from 2 hours to 16 hours, from 2 hours to 17 hours, from 2 hours to 18
hours, from 2
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hours to 19 hours, from 2 hours to 20 hours, from 2 hours to 21 hours, from 2
hours to 22 hours,
from 2 hours to 23 hours, from 2 hours to 24 hours, from 3 hours to 4 hours,
from 3 hours to 5
hours, from 3 hours to 6 hours, from 3 hours to 7 hours, from 3 hours to 8
hours, from 3 hours to
9 hours, from 3 hours to 10 hours, from 3 hours to 11 hours, from 3 hours to
12 hours, from 3
hours to 13 hours, from 3 hours to 14 hours, from 3 hours to 15 hours, from 3
hours to 16 hours,
from 3 hours to 17 hours, from 3 hours to 18 hours, from 3 hours to 19 hours,
from 3 hours to 20
hours, from 3 hours to 21 hours, from 3 hours to 22 hours, from 3 hours to 23
hours, from 3
hours to 24 hours, from 4 hours to 5 hours, from 4 hours to 6 hours, from 4
hours to 7 hours,
from 4 hours to 8 hours, from 4 hours to 9 hours, from 4 hours to 10 hours,
from 4 hours to 11
hours, from 4 hours to 12 hours, from 4 hours to 13 hours, from 4 hours to 14
hours, from 4
hours to 15 hours, from 4 hours to 16 hours, from 4 hours to 17 hours, from 4
hours to 18 hours,
from 4 hours to 19 hours, from 4 hours to 20 hours, from 4 hours to 21 hours,
from 4 hours to 22
hours, from 4 hours to 23 hours, from 4 hours to 24 hours, from 5 hours to 6
hours, from 5 hours
to 7 hours, from 5 hours to 8 hours, from 5 hours to 9 hours, from 5 hours to
10 hours, from 5
hours to 11 hours, from 5 hours to 12 hours, from 5 hours to 13 hours, from 5
hours to 14 hours,
from 5 hours to 15 hours, from 5 hours to 16 hours, from 5 hours to 17 hours,
from 5 hours to 18
hours, from 5 hours to 19 hours, from 5 hours to 20 hours, from 5 hours to 21
hours, from 5
hours to 22 hours, from 5 hours to 23 hours, from 5 hours to 24 hours, from 6
hours to 7 hours,
from 6 hours to 8 hours, from 6 hours to 9 hours, from 6 hours to 10 hours,
from 6 hours to 11
hours, from 6 hours to 12 hours, from 6 hours to 13 hours, from 6 hours to 14
hours, from 6
hours to 15 hours, from 6 hours to 16 hours, from 6 hours to 17 hours, from 6
hours to 18 hours,
from 6 hours to 19 hours, from 6 hours to 20 hours, from 6 hours to 21 hours,
from 6 hours to 22
hours, from 6 hours to 23 hours, from 6 hours to 24 hours, from 7 hours to 8
hours, from 7 hours
to 9 hours, from 7 hours to 10 hours, from 7 hours to 11 hours, from 7 hours
to 12 hours, from 7
hours to 13 hours, from 7 hours to 14 hours, from 7 hours to 15 hours, from 7
hours to 16 hours,
from 7 hours to 17 hours, from 7 hours to 18 hours, from 7 hours to 19 hours,
from 7 hours to 20
hours, from 7 hours to 21 hours, from 7 hours to 22 hours, from 7 hours to 23
hours, from 7
hours to 24 hours, from 8 hours to 9 hours, from 8 hours to 10 hours, from 8
hours to 11 hours,
from 8 hours to 12 hours, from 8 hours to 13 hours, from 8 hours to 14 hours,
from 8 hours to 15
hours, from 8 hours to 16 hours, from 8 hours to 17 hours, from 8 hours to 18
hours, from 8
hours to 19 hours, from 8 hours to 20 hours, from 8 hours to 21 hours, from 8
hours to 22 hours,
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from 8 hours to 23 hours, from 8 hours to 24 hours, from 9 hours to 10 hours,
from 9 hours to 11
hours, from 9 hours to 12 hours, from 9 hours to 13 hours, from 9 hours to 14
hours, from 9
hours to 15 hours, from 9 hours to 16 hours, from 9 hours to 17 hours, from 9
hours to 18 hours,
from 9 hours to 19 hours, from 9 hours to 20 hours, from 9 hours to 21 hours,
from 9 hours to 22
hours, from 9 hours to 23 hours, from 9 hours to 24 hours, from 10 hours to 11
hours, from 10
hours to 12 hours, from 10 hours to 13 hours, from 10 hours to 14 hours, from
10 hours to 15
hours, from 10 hours to 16 hours, from 10 hours to 17 hours, from 10 hours to
18 hours, from 10
hours to 19 hours, from 10 hours to 20 hours, from 10 hours to 21 hours, from
10 hours to 22
hours, from 10 hours to 23 hours, from 10 hours to 24 hours, from 11 hours to
12 hours, from 11
hours to 13 hours, from 11 hours to 14 hours, from 11 hours to 15 hours, from
11 hours to 16
hours, from 11 hours to 17 hours, from 11 hours to 18 hours, from 11 hours to
19 hours, from 11
hours to 20 hours, from 11 hours to 21 hours, from 11 hours to 22 hours, from
11 hours to 23
hours, from 11 hours to 24 hours, from 12 hours to 13 hours, from 12 hours to
14 hours, from 12
hours to 15 hours, from 12 hours to 16 hours, from 12 hours to 17 hours, from
12 hours to 18
hours, from 12 hours to 19 hours, from 12 hours to 20 hours, from 12 hours to
21 hours, from 12
hours to 22 hours, from 12 hours to 23 hours, from 12 hours to 24 hours, from
13 hours to 14
hours, from 13 hours to 15 hours, from 13 hours to 16 hours, from 13 hours to
17 hours, from 13
hours to 18 hours, from 13 hours to 19 hours, from 13 hours to 20 hours, from
13 hours to 21
hours, from 13 hours to 22 hours, from 13 hours to 23 hours, from 13 hours to
24 hours, from 14
hours to 16 hours, from 14 hours to 17 hours, from 14 hours to 18 hours, from
14 hours to 19
hours, from 14 hours to 20 hours, from 14 hours to 21 hours, from 14 hours to
22 hours, from 14
hours to 23 hours, from 14 hours to 24 hours, from 15 hours to 16 hours, from
15 hours to 17
hours, from 15 hours to 18 hours, from 15 hours to 19 hours, from 15 hours to
20 hours, from 15
hours to 21 hours, from 15 hours to 22 hours, from 15 hours to 23 hours, from
15 hours to 24
hours, from 16 hours to 17 hours, from 16 hours to 18 hours, from 16 hours to
19 hours, from 16
hours to 20 hours, from 16 hours to 21 hours, from 16 hours to 22 hours, from
16 hours to 23
hours, from 16 hours to 24 hours, from 17 hours to 18 hours, from 17 hours to
19 hours, from 17
hours to 20 hours, from 17 hours to 21 hours, from 17 hours to 22 hours, from
17 hours to 23
hours, from 17 hours to 24 hours, from 18 hours to 19 hours, from 18 hours to
20 hours, from 18
hours to 21 hours, from 18 hours to 22 hours, from 18 hours to 23 hours, from
18 hours to 24
hours, from 19 hours to 20 hours, from 19 hours to 21 hours, from 19 hours to
22 hours, from 19

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hours to 23 hours, from 19 hours to 24 hours, from 20 hours to 21 hours, from
20 hours to 22
hours, from 20 hours to 23 hours, from 20 hours to 24 hours, from 21 hours to
22 hours, from 21
hours to 23 hours, from 21 hours to 24 hours, from 22 hours to 23 hours, from
22 hours to 24
hours, or from 23 hours to 24 hours.
[0032] Optionally, the secondary lower temperature for homogenization,
after an initial
homogenization at higher temperature, is from 500 C to 580 C, such as from
500 C to 505 C,
from 500 C to 510 C, from 500 C to 515 C, from 500 C to 520 C, from 500
C to 525 C,
from 500 C to 530 C, from 500 C to 535 C, from 500 C to 540 C, from 500
C to 545 C,
from 500 C to 550 C, from 500 C to 555 C, from 500 C to 560 C, from 500
C to 565 C,
from 500 C to 570 C, from 500 C to 575 C, from 505 C to 510 C, from 505
C to 515 C,
from 505 C to 520 C, from 505 C to 525 C, from 505 C to 530 C, from 505
C to 535 C,
from 505 C to 540 C, from 505 C to 545 C, from 505 C to 550 C, from 505
C to 555 C,
from 505 C to 560 C, from 505 C to 565 C, from 505 C to 570 C, from 505
C to 575 C,
from 510 C to 515 C, from 510 C to 520 C, from 510 C to 525 C, from 510 C
to 530 C,
from 510 C to 535 C, from 510 C to 540 C, from 510 C to 545 C, from 510 C
to 550 C,
from 510 C to 555 C, from 510 C to 560 C, from 510 C to 565 C, from 510 C
to 570 C,
from 510 C to 575 C, from 510 C to 580 C, from 515 C to 520 C, from 515 C
to 525 C,
from 515 C to 530 C, from 515 C to 535 C, from 515 C to 540 C, from 515 C
to 545 C,
from 515 C to 550 C, from 515 C to 555 C, from 515 C to 560 C, from 515 C
to 565 C,
from 515 C to 570 C, from 515 C to 575 C, from 515 C to 580 C, from 520
C to 525 C,
from 520 C to 530 C, from 520 C to 535 C, from 520 C to 540 C, from 520
C to 545 C,
from 520 C to 550 C, from 520 C to 555 C, from 520 C to 560 C, from 520
C to 565 C,
from 520 C to 570 C, from 520 C to 575 C, from 520 C to 580 C, from 525
C to 530 C,
from 525 C to 535 C, from 525 C to 540 C, from 525 C to 545 C, from 525
C to 550 C,
from 525 C to 555 C, from 525 C to 560 C, from 525 C to 565 C, from 525
C to 570 C,
from 525 C to 575 C, from 525 C to 580 C, from 530 C to 535 C, from 530
C to 540 C,
from 530 C to 545 C, from 530 C to 550 C, from 530 C to 555 C, from 530
C to 560 C,
from 530 C to 565 C, from 530 C to 570 C, from 530 C to 575 C, from 530
C to 580 C,
from 535 C to 540 C, from 535 C to 545 C, from 535 C to 550 C, from 535
C to 555 C,
from 535 C to 560 C, from 535 C to 565 C, from 535 C to 570 C, from 535
C to 575 C,
from 535 C to 580 C, from 540 C to 545 C, from 540 C to 550 C, from 540
C to 555 C,
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from 540 C to 560 C, from 540 C to 565 C, from 540 C to 570 C, from 540
C to 575 C,
from 540 C to 580 C, from 545 C to 550 C, from 545 C to 555 C, from 545
C to 560 C,
from 545 C to 565 C, from 545 C to 570 C, from 545 C to 575 C, from 545
C to 580 C,
from 550 C to 555 C, from 550 C to 560 C, from 550 C to 565 C, from 550
C to 570 C,
from 550 C to 575 C, from 550 C to 580 C, from 555 C to 560 C, from 555
C to 565 C,
from 555 C to 570 C, from 555 C to 575 C, from 555 C to 580 C, from 560
C to 565 C,
from 560 C to 570 C, from 560 C to 575 C, from 560 C to 580 C, from 565
C to 570 C,
from 565 C to 575 C, from 565 C to 580 C, from 570 C to 575 C, from 570
C to 580 C,
or from 575 C to 580 C. In some embodiments, soaking the homogenized
aluminum alloy
product at the second homogenization temperature controls a surface quality or
characteristic of
the homogenized aluminum alloy product. Optionally, soaking the homogenized
aluminum
alloy product at the second homogenization temperature brings a temperature of
the
homogenized aluminum alloy product to a temperature sufficient for a rolling
process. Disclosed
methods may optionally include subjecting the homogenized aluminum alloy
product to one or
more rolling processes to produce a rolled aluminum alloy product.
[0033] Other objects and advantages will be apparent from the following
detailed description
of non-limiting examples.
BRIEF DESCRIPTION OF THE FIGURES
[0034] 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.
[0035] FIG. 1 provides an illustrative graph showing a relationship between
formability of an
aluminum alloy and average particle size according to some embodiments.
[0036] FIG. 2A provides a schematic illustration of an aluminum alloy
sample having
particles according to some embodiments.
[0037] FIG. 2B provides a schematic illustration of forces being exerted on
an aluminum
alloy sample having particles according to some embodiments.
[0038] FIG. 2C provides a schematic illustration of crack propagation in an
aluminum alloy
sample having particles according to some embodiments.
[0039] FIG. 2D provides a schematic illustration of cracking of an aluminum
alloy sample
having particles according to some embodiments.
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[0040] FIG. 3 provides an optical micrograph image of a crack propagating
through an
aluminum alloy having particles according some embodiments.
[0041] FIG. 4 provides a schematic overview of an example method for making
an
aluminum alloy product.
[0042] FIG. 5 provides a plot showing example homogenization conditions
used for making
aluminum alloy products.
[0043] FIG. 6 provides a method of making an aluminum alloy having
favorable particle
density and inter-particle spacing according to some embodiments.
[0044] FIG. 7A and FIG. 7B provide plots showing predicted equilibrium
phase diagrams for
two example 3xxx series aluminum alloys.
[0045] FIG. 8 provides electron micrograph images for samples of two
example 3xxx series
aluminum alloys as cast and after processing according to two different
processing regimes.
[0046] FIG. 9 provides electrical conductivity data for samples of two
example 3xxx series
aluminum alloys processed according to two different processing regimes.
[0047] FIG. 10 provides electron micrograph images for samples of two
example 3xxx series
aluminum alloys processed according to two different processing regimes.
[0048] FIG. 11 provides electron micrograph images for samples of two
example 3xxx series
aluminum alloys processed according to two different processing regimes.
[0049] FIG. 12 provides particle size distributions for samples of two
example 3xxx series
aluminum alloys processed according to two different processing regimes.
[0050] FIG. 13 provides images for samples of two example 3xxx series
aluminum alloys
processed according to two different processing regimes.
[0051] FIG. 14 provides images for samples of two example 3xxx series
aluminum alloys
processed according to two different processing regimes.
[0052] FIG. 15A and FIG. 15B provide charts showing tensile properties for
samples of two
example 3xxx series aluminum alloys processed according to two different
processing regimes.
[0053] FIG. 16A and FIG. 16B provide plots showing bendability test results
for samples of
two example 3xxx series aluminum alloys processed according to two different
processing
regimes.
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DETAILED DESCRIPTION
[0054] The present disclosure provides aluminum alloy products and methods
of making and
treating aluminum alloys and aluminum alloy products. In some examples, the
aluminum alloys
used in the methods and products described herein include, for example, 3xxx
series aluminum
alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, or 6xxx
series aluminum
alloys. In some examples, the aluminum alloys may include an alloy matrix
comprising
aluminum, magnesium, manganese, silicon, iron, and optionally copper. By way
of non-limiting
example, 3xxx series aluminum alloys may be particularly useful with the
disclosed methods and
products. Exemplary 3xxx series (also referred to herein as AA3xxx series)
aluminum alloys for
use in the methods and products described herein can include AA3002, AA3102,
AA3003,
AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204,
AA3304, AA3005, AA3005A, AA3405, AA3405A, AA3405B, AA3007, AA3407, AA3207,
AA3207A, AA3307, AA3009, AA3010, AA3410, AA3011, AA3012, AA3012A, AA3013,
AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026,
AA3030, AA3130, or AA3065.
[0055] Specifically, the present disclosure relates to aluminum alloy
products having
improved formability. Large particles formed within aluminum alloy products
may reduce the
formability of the aluminum alloy products because large particles can
increase cracking
susceptibility and can reduce the overall strength of aluminum alloy products.
Voids may form
around particles, especially large particles, within the aluminum alloy
material. Large particles
often have increased porosity, reduced ductility, and can be more brittle than
the aluminum alloy
material surrounding the particle. The difference in material properties
between the particles and
aluminum alloy matrix may concentrate stress or strain applied to the aluminum
alloy product
around the particles. The larger the particle, the greater the propensity for
stress or strain to
concentrate around the particle. For example, excess or overly large particles
may cause tear off
to occur during manufacturing processes, such as during drawing or necking of
the aluminum
alloy, because of the weak points formed around the particles. In other
scenarios, large particles
may cause an aluminum alloy product to split or fracture during use.
[0056] A general approach to increasing formability is to reduce particle
size. However,
when the alloy composition is fixed as particle size is reduced, the density
of particles within a
set volume of aluminum alloy increases, since the particles may simply
decrease in size by
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breaking into multiple smaller particles. Increased particle density may also
be detrimental to
the formability of aluminum alloy products. As particle density increases, the
particles become
closer together, on average, reducing the spacing between proximate particles
(inter-particle
spacing). Reduced or low inter-particle spacing may be problematic because
crack propagation
may take less energy when particles are spaced close together, as cracks may
preferentially
extend between particles. For example, when an aluminum alloy is under stress
or strain from
use or during the manufacturing process (i.e., being stretched or pulled),
cracks may form from
voids present around particles or weak points within the aluminum alloy. A
reduction in inter-
particle spacing may increase crack propagation from the weak points around
particles because
less energy may be required for the crack to reach the next nearest particle.
Thus, in some cases,
reducing particle size can actually be detrimental to the formability of
aluminum alloy products.
[0057] Accordingly, controlling particle size and inter-particle spacing
may be useful for
making aluminum alloy products having improved or optimal formability.
Advantageously, the
presently described aluminum alloy products may exhibit particle sizes and
inter-particle spacing
that limit or reduce tear off and/or stress induced cracking (i.e., improve
formability).
Specifically, the aluminum alloys disclosed herein may include an elemental
composition which
allows for formation of favorable particle size and favorable inter-particle
spacing.
[0058] The aluminum alloys disclosed herein may also allow for an increase
in recycled
source content. Increasing the recycled source content of an aluminum alloy
can reduce the
formability of the aluminum alloy product because of certain higher alloying
components present
within the recycled source content. Recycled source content is generally a
mixture of multiple
different types of materials. Thus, the composition of the recycled source
content can sometimes
include undesirable components in undesirable amounts. Generally, the mixed
composition may
create undesirable particles upon casting and/or processing. For example, the
particles may
exhibit undesirable composition, sizing, and/or spacing. Accordingly, by use
of the disclosed
techniques, particle size and particle density can be controlled to a level
that may be able to
compensate for the mixed composition and therefore be compatible with high
amounts of
recycled source content without impacting the formability character of the
resultant aluminum
alloy product.
[0059] Aluminum alloy products can be prepared by casting an aluminum alloy
to form a
cast aluminum alloy product and homogenizing the cast aluminum alloy product
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homogenized aluminum alloy product. During a casting process, aluminum alloy
products
containing iron and manganese may generate intermetallic particles comprising
Al and one or
more of Fe or Mn, which may be referred to herein as Al-(Fe, Mn) intermetallic
particles or f3-
phase intermetallic particles, within the cast aluminum alloy product. When
silicon is present,
intermetallic particles comprising Al, Si, and one or more of Fe or Mn, also
referred to herein as
Al-(Fe, Mn)-Si intermetallic particles or a-phase intermetallic particles, may
also be generated.
As some amounts of iron and silicon are generally present in almost all
aluminum alloys, many
aluminum alloys may include such intermetallic particles upon casting.
[0060] Each of these particle types exhibits different properties and
contributes in different
ways to the structure of the aluminum alloy. For example, 0-phase particles
tend to be larger and
more blocky or geometric than a-phase particles, while a-phase particles are
harder and tend to
be smaller than 0-phase particles, in general. During hot and cold rolling,
intermetallic particles
may be broken, impacting their size, distribution, and number density, for
example.
[0061] The presence of intermetallic particles in a cast aluminum alloy
product may be
beneficial. For example, aluminum alloys including intermetallic particles can
be beneficial for
forming aluminum beverage containers since the intermetallic particles may be
significantly
harder than other portions of the aluminum alloy product. During drawing,
ironing, and necking,
the hard intermetallic particles can reduce galling by cleaning die surfaces.
For example, the
intermetallic particles may abrade drawing, ironing, and necking dies and
reduce or remove
metal built up on the die surfaces.
[0062] As the beverage container making process progresses through various
drawing,
ironing, and necking processes, wall thicknesses are reduced. The presence of
0-phase
intermetallic particles may be detrimental, however, when wall thicknesses are
reduced during
these processes if the 0-phase particles are too large or present at too high
of an amount. Excess
or overly large 0-phase particles may cause tear off to occur during drawing
or necking, where
the beverage container wall splits or fractures, damaging the beverage
container wall. Tear off,
in some cases, may interrupt the manufacturing processes, as wall portions may
completely
separate from a damaged beverage container and may need to be removed from
within the die or
other manufacturing equipment.
[0063] Advantageously, however, the presently described aluminum alloy
products exhibit
intermetallic particle sizes, distributions, concentrations, and compositions
that limit or reduce
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tear off. By using an increased ratio of silicon to iron, the disclosed
aluminum alloy products
may preferentially generate a-phase intermetallic particles, such as by
converting 0-phase
intermetallic particles to a-phase intermetallic particles during a
homogenization process.
[0064] Further, during homogenization at high temperatures, alloying
elements may diffuse
and migrate throughout a crystal structure of a cast aluminum alloy product
and change the size,
distribution, concentration, and composition of intermetallic particles. For
example, silicon
atoms present in the aluminum crystal structure may diffuse into 0-phase
intermetallic particles
and transform the particles into a-phase intermetallic particles. Since
silicon may be present in
low amounts, such as less than about 1 wt. %, it may take significant time for
silicon to diffuse
and accumulate in the 0-phase intermetallic particles in the cast product, so
long duration
homogenization may be useful for effecting significant transformation of 0-
phase intermetallic
particles. By homogenizing at high temperatures for a time duration greater
than 12 hours or 24
hours, for example, silicon from the aluminum alloy may diffuse and transform
at least a fraction
of the 0-phase intermetallic particles into a-phase intermetallic particles.
[0065] Example homogenization conditions may include soaking a cast
aluminum alloy
product at a high temperature for 12 hours or 24 hours or more. For example,
soaking may occur
at a homogenization temperature of from about 575 C to about 615 C, from
about 580 C to
about 610 C, or from about 585 C to about 605 C. A secondary homogenization
process may
also be useful for some embodiments. For example, a temperature of the
homogenized
aluminum alloy product may be reduced to a lower temperature and the aluminum
alloy product
may be held (soaked) at the lower temperature for a particular time duration.
Example secondary
homogenization temperatures include from about 500 C to about 600 C, and may
be dependent
upon the particular alloy. Example secondary homogenization soak time
durations include from
about 1 hour to about 24 hours. A secondary homogenization at reduced
temperature of this type
may be useful for controlling and/or improving a surface quality or
characteristic of the
homogenized aluminum alloy product.
[0066] During homogenization, the size, composition, concentration, and
distribution of
intermetallic particles may change. For example, 0-phase intermetallic
particles may take up
silicon atoms and be transformed into a-phase particles, at least in part,
which may reduce the
sizes of any residual 0-phase intermetallic particles. Thus, an average size
of 0-phase
intermetallic particles may decrease during homogenization or soaking.
Similarly, a number
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density of 0-phase intermetallic particles may decrease during homogenization
or soaking. In
some embodiments, an amount of 0-phase intermetallic particles are transformed
into a-phase
intermetallic particles during homogenization or soaking, such as from about
30% to about
100%. A number density of a-phase intermetallic particles may increase during
homogenization
or soaking. Number density ratios of a-phase intermetallic particles to 0-
phase intermetallic
particles of from about 2 to about 1000 may be achieved by the long duration
homogenization
processes described herein. As cast, however, number density ratios of a-phase
intermetallic
particles to 0-phase intermetallic particles may be from about 0.3 to about 3
for example.
[0067] Aluminum alloys used for the methods and products described herein
may correspond
to recycled materials, such as recycled beverage containers. In the process of
casting the
aluminum alloys, source materials, such as recycled beverage containers may be
melted to
prepare a molten aluminum alloy. As beverage containers tend to include 3xxx
series
manganese containing aluminum alloys (e.g., AA3104) and 5xxx series magnesium
containing
aluminum alloys (e.g., AA5182), this source material may be useful for
preparing new aluminum
alloy products for making new beverage containers. For cases where a silicon
to iron ratio (e.g.,
wt. % ratio) is to be increased to obtain the benefits described above with
respect to intermetallic
particles, an additional source of silicon may be used. For example, other
silicon containing
alloys may be added to the molten aluminum, such as a 4xxx series aluminum
alloy or a 6xxx
series aluminum alloy. In some cases, these sources of supplemental silicon
may correspond to
recycled aluminum alloy materials.
[0068] Non-limiting exemplary AA4xxx series alloys for use in the methods
described
herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010,
AA4013,
AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020,
AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943,
AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.
[0069] Non-limiting exemplary AA6xxx series alloys for use in the methods
described
herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501,
AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205,
AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110,
AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015,
AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023,
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AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040,
AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053,
AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B,
AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A,
AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065,
AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A,
AA6182, AA6091, or AA6092.
Definitions and Descriptions:
[0070] 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.
[0071] In this description, reference is made to alloys identified by AA
numbers and other
related 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.
[0072] As used herein, a plate generally has a thickness of greater than
about 15 mm. For
example, a plate may refer to an aluminum alloy 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.
[0073] 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, 5
mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.
[0074] As used herein, a sheet generally refers to an aluminum alloy
product having a
thickness of less than about 4 mm. For example, a sheet may have a thickness
of less than about
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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).
[0075] 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.
[0076] 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, 16 C, 17 C, 18 C,
19 C, 20 C, 21
C, 22 C, 23 C, 24 C, 25 C, 26 C, 27 C, 28 C, 29 C, or 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 4050 mbar. For example, relative humidity can be about 20%,
21%, 22%, 23%,
24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%,
39%,
40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%,
55%,
56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%,
71%,
72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%,
87%,
88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 100%, or anywhere
in
between. For example, barometric pressure can be about 975 mbar, 980 mbar, 985
mbar, 990
mbar, 995 mbar, 1000 mbar, 1005 mbar, 1010 mbar, 1015 mbar, 1020 mbar, 1025
mbar, 1030
mbar, 1035 mbar, 1040 mbar, 1045 mbar, 4050 mbar, or anywhere in between.
[0077] 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. %).
[0078] As used herein, the meaning of "a," "an," and "the" includes
singular and plural
references unless the context clearly dictates otherwise.

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Particle Size and Inter-particle Spacing for Aluminum Alloys and Aluminum
Alloy Products
[0079] Aspects of the present disclosure relate to aluminum alloy products
and methods of
making aluminum alloy products that have favorable particle size and inter-
particle spacing for
improved formability. For example, the disclosed aluminum alloy products may
have an
elemental composition that allows for generation of favorable particle sizes
while maintaining
inter-particle spacing at a level sufficient to reduce crack formation and
propagation. Generally,
to increase formability of an aluminum alloy product, the size of included
particles, such as
intermetallic particles, may be reduced. However, as particle size within an
aluminum alloy
product is reduced, the particle density may increase and the inter-particle
spacing may decrease.
Undesirably, when the inter-particle spacing becomes low, this may increase
cracking
susceptibility and be detrimental to formability. The disclosed methods,
techniques and
products, however, overcome this characteristic by controlling the inter-
particle spacing and
particle size to a level which minimizes or reduces crack susceptibility and
crack propagation,
resulting in a product with improved formability characteristics.
[0080] FIG. 1 provides a graph 100 that illustrates the relationship
between average particle
size and formability. Line 110 corresponds to a theoretical approach to
improving formability.
The theoretical approach depicted by line 110 may illustrate the conventional
approach to
improving formability by reducing particle size. As shown by line 110, as
particle size increases
the formability of the aluminum alloy product should decrease. Conversely, as
particle size
decreases, theoretically, formability should increase. Such a relationship,
however, does not
hold true in practice when the overall composition of the aluminum alloy
product is held
constant. For example, when the average particle size decreases at fixed
composition, the
quantity and number density must increase, as large particles are broken down
into more
particles of smaller size. Line 120 shows that, in practice, the relationship
between particle size
and product formability may not be linear. Instead, the relationship between
particle size and
product formability may be non-linear, and reflect an optimal formability
character at a mid-
range particle size. Following line 120 starting from the origin, as particle
size increases,
formability may increase as well within an initial range of particle size.
However, once the
particle size reaches a certain point, the formability of the product may
begin to decrease again.
The relationship of formability and particle size illustrated by line 120 may
be representative of
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how both particle size and inter-particle spacing impact the formability of an
aluminum alloy
product.
[0081] A reduction in particle size may result in an increase of particle
density within a set
volume of aluminum alloy when the composition remains fixed. An increased
density may mean
that the particles are positioned closer to each other, or, stated another
way, the inter-particle
spacing between particles may be reduced. Small inter-particle spacing may be
detrimental to
formability because the shorter the inter-particle spacing, the more
susceptible the aluminum
alloy may be to crack propagation, as it may be easier (i.e., require less
force) for a crack to
propagate from one particle to the next particle to the next particle, and so
on. However,
increasing inter-particle spacing may necessitate larger particle sizes when
the composition is
fixed (i.e., when the total volume or mass of the particles is held constant),
resulting in formation
of larger particles and a reduction in the number density of the particles.
While an increase in
inter-particle spacing may require more energy or force for a crack to
propagate from particle to
particle, reducing cracking susceptibility to some extent, the resulting
larger particles may still
act as crack initiation or weak points. As previously noted, larger particles
tend to form voids
within the aluminum alloy material which can concentrate deformation forces
when the
aluminum alloy product is under stress or strain. Thus, while larger particles
may correspond to
larger inter-particle spacing, making crack propagation more energy intensive,
larger particles
may also act as crack initiation points, leading to more overall weak points
within the aluminum
alloy. Thus, to achieve optimal formability, particle size and inter-particle
spacing must be
balanced. FIGs. 2A-2D provide schematic illustrations of an aluminum alloy
sample, depicting
how smaller particle sizes may detrimentally affect the formability of an
aluminum alloy. In
FIG. 2A, an aluminum alloy 210 is illustrated. Aluminum alloy 210 includes a
plurality of
particles 220. Particles 220 may include various types of particles. For
example, the plurality of
particles 220 may include one or more of constituent particles, intermetallic
particles, oxides,
precipitate or hardening particles. In some embodiments, particles 220 may
include iron-
containing particles and/or manganese dispersoids. Particles 220 may include
one or more
intermetallic particles. For example, particles 220 may include a-phase
intermetallic particles
and 0-phase intermetallic particles. Aluminum alloy 210 may have a higher
proportion of a-
phase intermetallic particles than 0-phase intermetallic particles, which may
correspond to a low
average particle size, since a-phase intermetallic particles may tend to be
smaller and less blocky
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than 0-phase intermetallic particles. In some embodiments, the iron-containing
particles may
account for from 1% to 4% of the total volume of the aluminum alloy. For
example, the iron-
containing particles may account for 1% to 2%, from 1% to 3%, from 2% to 3%,
from 2% to 4%,
or from 3% to 4% of the total volume of the aluminum alloy. In some
embodiments, the iron-
containing particles may have a diameter from 1 p.m to 40 p.m, such as from 2
p.m to 40 pm, 5
p.m to 40 p.m, 7 p.m to 40 pm, 10 p.m to 40 p.m, 15 p.m to 40 p.m, 20 p.m to
40 p.m, 25 p.m to 40
p.m, 30 p.m to 40 p.m, or 35 p.m to 40 p.m. In some embodiments, the reference
to particle
diameters for the iron-containing particles may be for the majority of the
iron-containing
particles. For example, a description that the iron-containing particles have
a diameter of from 1
p.m to 40 p.m may mean that the majority (i.e., greater than 50%) of the iron-
containing particles
have a diameter of 1 p.m to 40 p.m or that 80% of the of the iron-containing
particles have a
diameter of 1 p.m to 40 p.m.
[0082] In FIG. 2B, force 230 is shown applied to aluminum alloy 210. Force
230 may
exemplify forces commonly applied during a manufacturing process or during use
of a product
produced from aluminum alloy 210. For example, the aluminum alloy 210 may be
placed under
stress during a drawing process, a rolling process, a stamping process, or the
like. In some cases,
force 230 may represent forces applied after manufacturing, such as directly
to an aluminum
alloy product or article prepared from aluminum alloy 210.
[0083] Force 230 may cause cracks 240 to initiate around particles 220 and
propagate
through aluminum alloy 210, as illustrated in FIG. 2C. As noted above,
particles 220 may act as
weak points or force concentration points within aluminum alloy 210. While
larger particles
tend to form larger weak points, smaller particles may also act as weak points
by forming voids
or concentrating deformation forces when force 230 is applied. In part,
because particles 220
have a different material composition than the bulk of aluminum alloy 210, the
interface between
the particles and the surrounding alloy may act as weak points, for example.
Differences in
hardness, porosity, ductility, and brittleness may all affect the formation of
a weak point around
particles 220.
[0084] As illustrated in FIG. 2B, particles 220 may be separated as
depicted by inter-particle
spacing 225. Inter-particle spacing 225 may correspond to the average or
shortest distance
between two particles. As noted above, in some embodiments, inter-particle
spacing 225 may
directly correlate to particle density if the volume fraction of particles 220
remains the same. For
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example, as the density of particles increases, inter-particle spacing 225 may
decrease.
Conversely, as the density of particles decreases, inter-particle spacing 225
may increase.
[0085] FIGs. 2C and 2D may illustrate how a decrease in inter-particle
spacing 225 may be
detrimental to formability. When inter-particle spacing 225 becomes too small,
cracks 240 may
easily propagate between particles 220. As shown in FIG. 2C, propagation of
cracks 240 may
follow a lowest energy path. For example, cracks 240 may propagate to the next
closest weak
point, such as particle 220, within aluminum alloy 210. If inter-particle
spacing 225 is lowered,
then it may take less energy for crack 240 to propagate from one particle to
the next. Less
energy may correspond to less material for crack 240 to move through. In
contrast, if inter-
particle spacing 225 is higher, more energy may be required for crack 240 to
propagate to the
next weak point because there is more material between the crack initiation
point and the
imperfection.
[0086] When particle density is increased and inter-particle spacing 225 is
decreased, cracks
240 may easily propagate to nearby particles 220. This may result in a domino-
effect of crack
propagation and eventually lead to complete fracturing or shearing 250 of
aluminum alloy 210,
as depicted at FIG. 2D. Fracturing or shearing 250 may result in breakage or
where large pieces
of aluminum alloy 210 separate from the bulk of aluminum alloy 210. Fracturing
250 may
impact the integrity and strength of aluminum alloy 210.
[0087] FIG. 3 provides an optical micrograph image 300 of a crack 340
propagating between
a large imperfection 350 and particle 320 within an aluminum alloy. The
aluminum alloy
depicted in FIG. 3 may correspond to an aluminum alloy having smaller particle
sizes and an
overall small average inter-particle spacing 325. In some cases, imperfection
350 may be a void,
crack or crack initiation point, weak point, or another particle within the
aluminum alloy. As
shown in image 300, crack 340 may propagate between imperfection 350 and the
next closest
particle 320. An additional imperfection 352 may be present or form around
particle 320. In
some cases, imperfection 352 may act as a weak point. Crack 340 may propagate
to particle 320
along a low energy path between imperfection 350 and imperfection 352. When
further stress or
force is applied, cracks may become larger and spur further propagation.
[0088] The aluminum alloys and related products discussed herein may
achieve favorable
inter-particle spacing while maintaining favorable particle size. In some
embodiments, the
aluminum alloys as provided herein may have an inter-particle spacing from
about 1 p.m to about
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25 p.m. For example, the inter-particle spacing may be from about 1 p.m to
about 25 p.m, from 1
p.m to 2 p.m, from 1 p.m to 5 p.m, from 1 p.m to 7 p.m, from 1 p.m to 10 p.m,
from 1 p.m to 12 p.m,
from 1 p.m to 15 p.m, from 1 p.m to 17 p.m, from 1 p.m to 20 p.m, from 1 p.m
to 22 p.m, from 1
p.m to 25 p.m, from 2 p.m to 5 p.m, from 2 p.m to 7 p.m, from 2 p.m to 10 p.m,
from 2 p.m to 12
p.m, from 2 p.m to 15 p.m, from 2 p.m to 17 p.m, from 2 p.m to 20 p.m, from 2
p.m to 22 p.m, from
2 p.m to 25 p.m, from 5 p.m to 7 p.m, from 5 p.m to 10 pm, from 5 p.m to 12
p.m, from 5 p.m to 15
p.m, from 5 p.m to 17 p.m, from 5 p.m to 20 p.m, from 5 p.m to 22 p.m, from 5
p.m to 25 p.m, from
7 p.m to 10 pm, from 7 p.m to 12 pm, from 7 p.m to 15 p.m, from 7 p.m to 17
p.m, from 7 p.m to
20 pm, from 7 p.m to 22 p.m, from 7 p.m to 25 p.m, from 10 p.m to 12 pm, from
10 p.m to 15 pm,
from 10 p.m to 17 pm, from 10 p.m to 20 p.m, from 10 p.m to 22 pm, from 10 p.m
to 25 p.m, from
12 p.m to 15 pm, from 12 p.m to 17 p.m, from 12 p.m to 20 p.m, from 12 p.m to
22 p.m, from 12
p.m to 25 p.m, from 15 p.m to 17 p.m, from 15 p.m to 20 p.m, from 15 p.m to 22
p.m, from 15 p.m
to 25 p.m, from 17 p.m to 20 p.m, from 17 p.m to 22 p.m, from 17 p.m to 25
p.m, from 20 p.m to 22
p.m, from 20 p.m to 25 p.m, or from 22 p.m to 25 p.m. In some embodiments,
inter-particle
spacing may be described with relation to the majority (greater than 50%) of
the plurality of
particles. For example, 80 percent or more of the plurality of particles
within an aluminum alloy
may have inter-particle spacing from 1 p.m to 25 p.m.
[0089] To
achieve favorable inter-particle spacing, the size and density of particles
within
the aluminum alloys may be controlled or limited. A particle density may be
represented as a
number of particles per unit volume (e.g., particles per p.m3) or as a number
of particles per unit
area (e.g., particles per p.m2). Use of particle density as a number of
particles per unit area may
be useful for quickly characterizing the number of particles in an aluminum
alloy or product by
obtaining a scanning electron micrograph image or an optical micrograph image
of a region of
the aluminum alloy or product and counting the number of particles in the
image, which may
represent a 2-dimensional slice of the aluminum alloy or product. In some
examples, multiple
images can be obtained to provide a representative sample of the aluminum
alloy or product,
such as for counting particles or establishing a particle density. In some
examples, the aluminum
alloys may have or be controlled to have a particle density of 5 to 30,000
particles per p.m2 (e.g.,
8 to 1,400 particles per p.m2) while maintaining particle diameters from 100
nm to 50 p.m. As
used herein, particle diameters may be used to quantify particle size. In some
cases, the particle
density and/or diameters are characterized by obtaining scanning electron
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or optical micrograph image(s) of a region or regions of the aluminum alloy or
product and
counting or evaluating the particles in the image(s).
[0090] In
some cases, particle density may be from 5 to 30,000 particles per um2, such
as
from 10 to 25,000, from 10 to 20,000, from 10 to 15,000, from 10 to 10,000,
from 10 to 9,500,
from 10 to 9,000, from 10 to 8,500, from 10 to 8,000, from 10 to 7,500, from
10 to 7,000, from
to 6,500, from 10 to 6,000, from 10 to 5,500, from 10 to 5,000, from 10 to
4,500, from 10 to
4,000, from 10 to 3,500, from 10 to 3,000, from 10 to 2,500, from 10 to 2,000,
from 10 to 1,500,
from 10 to 1,000, from 10 to 950, from 10 to 900, from 10 to 850, from 10 to
800, from 10 to
750, from 10 to 700, from 10 to 650, from 10 to 600, from 10 to 550, from 10
to 500, from 10 to
450, from 10 to 400, from 10 to 350, from 10 to 300, from 10 to 250, from 10
to 200, from 10 to
150, from 10 to 100, from 10 to 75, from 10 to 50, from 10 to 25, from 25 to
30,000, from 25 to
25,000, from 25 to 20,000, from 25 to 15,000, from 25 to 10,000, from 25 to
9,500, from 25 to
9,000, from 25 to 8,500, from 25 to 8,000, from 25 to 7,500, from 25 to 7,000,
from 25 to 6,500,
from 25 to 6,000, from 25 to 5,500, from 25 to 5,000, from 25 to 4,500, from
25 to 4,000, from
25 to 3,500, from 25 to 3,000, from 25 to 2,500, from 25 to 2,000, from 25 to
1,500, from 25 to
1,000, from 25 to 950, from 25 to 900, from 25 to 850, from 25 to 800, from 25
to 750, from 25
to 700, from 25 to 650, from 25 to 600, from 25 to 550, from 25 to 500, from
25 to 450, from 25
to 400, from 25 to 350, from 25 to 300, from 25 to 250, from 25 to 200, from
25 to 150, from 25
to 100, from 25 to 75, from 25 to 50, from 50 to 30,000, from 50 to 25,000,
from 50 to 20,000,
from 50 to 15,000, from 50 to 10,000, from 50 to 9,500, from 50 to 9,000, from
50 to 8,500,
from 50 to 8,000, from 50 to 7,500, from 50 to 7,000, from 50 to 6,500, from
50 to 6,000, from
50 to 5,500, from 50 to 5,000, from 50 to 4,500, from 50 to 4,000, from 50 to
3,500, from 50 to
3,000, from 50 to 2,500, from 50 to 2,000, from 50 to 1,500, from 50 to 1,000,
from 50 to 950,
from 50 to 900, from 50 to 850, from 50 to 800, from 50 to 750, from 50 to
700, from 50 to 650,
from 50 to 600, from 50 to 550, from 50 to 500, from 50 to 450, from 50 to
400, from 50 to 350,
from 50 to 300, from 50 to 250, from 50 to 200, from 50 to 150, from 50 to
100, from 50 to 75,
from 75 to 30,000, from 75 to 25,000, from 75 to 20,000, from 75 to 15,000,
from 75 to 10,000,
from 75 to 9,500, from 75 to 9,000, from 75 to 8,500, from 75 to 8,000, from
75 to 7,500, from
75 to 7,000, from 75 to 6,500, from 75 to 6,000, from 75 to 5,500, from 75 to
5,000, from 75 to
4,500, from 75 to 4,000, from 75 to 3,500, from 75 to 3,000, from 75 to 2,500,
from 75 to 2,000,
from 75 to 1,500, from 75 to 1,000, from 75 to 950, from 75 to 900, from 75 to
850, from 75 to
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800, from 75 to 750, from 75 to 700, from 75 to 650, from 75 to 600, from 75
to 550, from 75 to
500, from 75 to 450, from 75 to 400, from 75 to 350, from 75 to 300, from 75
to 250, from 75 to
200, from 75 to 150, from 75 to 100, from 100 to 30,000, from 100 to 25,000,
from 100 to
20,000, from 100 to 15,000, from 100 to 10,000, from 100 to 9,500, from 100 to
9,000, from 100
to 8,500, from 100 to 8,000, from 100 to 7,500, from 100 to 7,000, from 100 to
6,500, from 100
to 6,000, from 100 to 5,500, from 100 to 5,000, from 100 to 4,500, from 100 to
4,000, from 100
to 3,500, from 100 to 3,000, from 100 to 2,500, from 100 to 2,000, from 100 to
1,500, from 100
to 1,000, from 100 to 950, from 100 to 900, from 100 to 850, from 100 to 800,
from 100 to 750,
from 100 to 700, from 100 to 650, from 100 to 600, from 100 to 550, from 100
to 500, from 100
to 450, from 100 to 400, from 100 to 350, from 100 to 300, from 100 to 250,
from 100 to 200,
from 100 to 150, from 150 to 30,000, from 150 to 25,000, from 150 to 20,000,
from 150 to
15,000, from 150 to 10,000, from 150 to 9,500, from 150 to 9,000, from 150 to
8,500, from 150
to 8,000, from 150 to 7,500, from 150 to 7,000, from 150 to 6,500, from 150 to
6,000, from 150
to 5,500, from 150 to 5,000, from 150 to 4,500, from 150 to 4,000, from 150 to
3,500, from 150
to 3,000, from 150 to 2,500, from 150 to 2,000, from 150 to 1,500, from 150 to
1,000, from 150
to 950, from 150 to 900, from 150 to 850, from 150 to 800, from 150 to 750,
from 150 to 700,
from 150 to 650, from 150 to 600, from 150 to 550, from 150 to 500, from 150
to 450, from 150
to 400, from 150 to 350, from 150 to 300, from 150 to 250, from 150 to 200,
from 200 to 30,000,
from 200 to 25,000, from 200 to 20,000, from 200 to 15,000, from 200 to
10,000, from 200 to
9,500, from 200 to 9,000, from 200 to 8,500, from 200 to 8,000, from 200 to
7,500, from 200 to
7,000, from 200 to 6,500, from 200 to 6,000, from 200 to 5,500, from 200 to
5,000, from 200 to
4,500, from 200 to 4,000, from 200 to 3,500, from 200 to 3,000, from 200 to
2,500, from 200 to
2,000, from 200 to 1,500, from 200 to 1,000, from 200 to 950, from 200 to 900,
from 200 to 850,
from 200 to 800, from 200 to 750, from 200 to 700, from 200 to 650, from 200
to 600, from 200
to 550, from 200 to 500, from 200 to 450, from 200 to 400, from 200 to 350,
from 200 to 300,
from 200 to 250, from 250 to 30,000, from 250 to 25,000, from 250 to 20,000,
from 250 to
15,000, from 250 to 10,000, from 250 to 9,500, from 250 to 9,000, from 250 to
8,500, from 250
to 8,000, from 250 to 7,500, from 250 to 7,000, from 250 to 6,500, from 250 to
6,000, from 250
to 5,500, from 250 to 5,000, from 250 to 4,500, from 250 to 4,000, from 250 to
3,500, from 250
to 3,000, from 250 to 2,500, from 250 to 2,000, from 250 to 1,500, from 250 to
1,000, from 250
to 950, from 250 to 900, from 250 to 850, from 250 to 800, from 250 to 750,
from 250 to 700,
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from 250 to 650, from 250 to 600, from 250 to 550, from 250 to 500, from 250
to 450, from 250
to 400, from 250 to 350, from 250 to 300, from 300 to 30,000, from 300 to
25,000, from 300 to
20,000, from 300 to 15,000, from 300 to 10,000, from 300 to 9,500, from 300 to
9,000, from 300
to 8,500, from 300 to 8,000, from 300 to 7,500, from 300 to 7,000, from 300 to
6,500, from 300
to 6,000, from 300 to 5,500, from 300 to 5,000, from 300 to 4,500, from 300 to
4,000, from 300
to 3,500, from 300 to 3,000, from 300 to 2,500, from 300 to 2,000, from 300 to
1,500, from 300
to 1,000, from 300 to 950, from 300 to 900, from 300 to 850, from 300 to 800,
from 300 to 750,
from 300 to 700, from 300 to 650, from 300 to 600, from 300 to 550, from 300
to 500, from 300
to 450, from 300 to 400, from 300 to 350, from 350 to 30,000, from 350 to
25,000, from 350 to
20,000, from 350 to 15,000, from 350 to 10,000, from 350 to 9,500, from 350 to
9,000, from 350
to 8,500, from 350 to 8,000, from 350 to 7,500, from 350 to 7,000, from 350 to
6,500, from 350
to 6,000, from 350 to 5,500, from 350 to 5,000, from 350 to 4,500, from 350 to
4,000, from 350
to 3,500, from 350 to 3,000, from 350 to 2,500, from 350 to 2,000, from 350 to
1,500, from 350
to 1,000, from 350 to 950, from 350 to 900, from 350 to 850, from 350 to 800,
from 350 to 750,
from 350 to 700, from 350 to 650, from 350 to 600, from 350 to 550, from 350
to 500, from 350
to 450, from 350 to 400, from 400 to 30,000, from 400 to 25,000, from 400 to
20,000, from 400
to 15,000, from 400 to 10,000, from 400 to 9,500, from 400 to 9,000, from 400
to 8,500, from
400 to 8,000, from 400 to 7,500, from 400 to 7,000, from 400 to 6,500, from
400 to 6,000, from
400 to 5,500, from 400 to 5,000, from 400 to 4,500, from 400 to 4,000, from
400 to 3,500, from
400 to 3,000, from 400 to 2,500, from 400 to 2,000, from 400 to 1,500, from
400 to 1,000, from
400 to 950, from 400 to 900, from 400 to 850, from 400 to 800, from 400 to
750, from 400 to
700, from 400 to 650, from 400 to 600, from 400 to 550, from 400 to 500, from
400 to 450, from
450 to 30,000, from 450 to 25,000, from 450 to 20,000, from 450 to 15,000,
from 450 to 10,000,
from 450 to 9,500, from 450 to 9,000, from 450 to 8,500, from 450 to 8,000,
from 450 to 7,500,
from 450 to 7,000, from 450 to 6,500, from 450 to 6,000, from 450 to 5,500,
from 450 to 5,000,
from 450 to 4,500, from 450 to 4,000, from 450 to 3,500, from 450 to 3,000,
from 450 to 2,500,
from 450 to 2,000, from 450 to 1,500, from 450 to 1,000, from 450 to 950, from
450 to 900,
from 450 to 850, from 450 to 800, from 450 to 750, from 450 to 700, from 450
to 650, from 450
to 600, from 450 to 550, from 450 to 500, from 500 to 30,000, from 500 to
25,000, from 500 to
20,000, from 500 to 15,000, from 500 to 10,000, from 500 to 9,500, from 500 to
9,000, from 500
to 8,500, from 500 to 8,000, from 500 to 7,500, from 500 to 7,000, from 500 to
6,500, from 500
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to 6,000, from 500 to 5,500, from 500 to 5,000, from 500 to 4,500, from 500 to
4,000, from 500
to 3,500, from 500 to 3,000, from 500 to 2,500, from 500 to 2,000, from 500 to
1,500, from 500
to 1,000, from 500 to 950, from 500 to 900, from 500 to 850, from 500 to 800,
from 500 to 750,
from 500 to 700, from 500 to 650, from 500 to 600, from 500 to 550, from 600
to 30,000, from
600 to 25,000, from 600 to 20,000, from 600 to 15,000, from 600 to 10,000,
from 600 to 9,500,
from 600 to 9,000, from 600 to 8,500, from 600 to 8,000, from 600 to 7,500,
from 600 to 7,000,
from 600 to 6,500, from 600 to 6,000, from 600 to 5,500, from 600 to 5,000,
from 600 to 4,500,
from 600 to 4,000, from 600 to 3,500, from 600 to 3,000, from 600 to 2,500,
from 600 to 2,000,
from 600 to 1,500, from 600 to 1,000, from 600 to 950, from 600 to 900, from
600 to 850, from
600 to 800, from 600 to 750, from 600 to 700, from 600 to 650, from 700 to
30,000, from 700 to
25,000, from 700 to 20,000, from 700 to 15,000, from 700 to 10,000, from 700
to 9,500, from
700 to 9,000, from 700 to 8,500, from 700 to 8,000, from 700 to 7,500, from
700 to 7,000, from
700 to 6,500, from 700 to 6,000, from 700 to 5,500, from 700 to 5,000, from
700 to 4,500, from
700 to 4,000, from 700 to 3,500, from 700 to 3,000, from 700 to 2,500, from
700 to 2,000, from
700 to 1,500, from 700 to 1,000, from 700 to 950, from 700 to 900, from 700 to
850, from 700 to
800, from 700 to 750, from 800 to 30,000, from 800 to 25,000, from 800 to
20,000, from 800 to
15,000, from 800 to 10,000, from 800 to 9,500, from 800 to 9,000, from 800 to
8,500, from 800
to 8,000, from 800 to 7,500, from 800 to 7,000, from 800 to 6,500, from 800 to
6,000, from 800
to 5,500, from 800 to 5,000, from 800 to 4,500, from 800 to 4,000, from 800 to
3,500, from 800
to 3,000, from 800 to 2,500, from 800 to 2,000, from 800 to 1,500, from 800 to
1,000, from 800
to 950, from 800 to 900, from 800 to 850, from 900 to 30,000, from 900 to
25,000, from 900 to
20,000, from 900 to 15,000, from 900 to 10,000, from 900 to 9,500, from 900 to
9,000, from 900
to 8,500, from 900 to 8,000, from 900 to 7,500, from 900 to 7,000, from 900 to
6,500, from 900
to 6,000, from 900 to 5,500, from 900 to 5,000, from 900 to 4,500, from 900 to
4,000, from 900
to 3,500, from 900 to 3,000, from 900 to 2,500, from 900 to 2,000, from 900 to
1,500, from 900
to 1,000, from 900 to 950, from 1,000 to 30,000, from 1,000 to 25,000, from
1,000 to 20,000,
from 1,000 to 15,000, from 1,000 to 10,000, from 1,000 to 9,500, from 1,000 to
9,000, from
1,000 to 8,500, from 1,000 to 8,000, from 1,000 to 7,500, from 1,000 to 7,000,
from 1,000 to
6,500, from 1,000 to 6,000, from 1,000 to 5,500, from 1,000 to 5,000, from
1,000 to 4,500, from
1,000 to 4,000, from 1,000 to 3,500, from 1,000 to 3,000, from 1,000 to 2,500,
from 1,000 to
2,000, from 1,000 to 1,500, from 2,000 to 30,000, from 2,000 to 25,000, from
2,000 to 20,000,
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from 2,000 to 15,000, from 2,000 to 10,000, from 2,000 to 9,500, from 2,000 to
9,000, from
2,000 to 8,500, from 2,000 to 8,000, from 2,000 to 7,500, from 2,000 to 7,000,
from 2,000 to
6,500, from 2,000 to 6,000, from 2,000 to 5,500, from 2,000 to 5,000, from
2,000 to 4,500, from
2,000 to 4,000, from 2,000 to 3,500, from 2,000 to 3,000, from 2,000 to 2,500,
from 3,000 to
30,000, from 3,000 to 25,000, from 3,000 to 20,000, from 3,000 to 15,000, from
3,000 to 10,000,
from 3,000 to 9,500, from 3,000 to 9,000, from 3,000 to 8,500, from 3,000 to
8,000, from 3,000
to 7,500, from 3,000 to 7,000, from 3,000 to 6,500, from 3,000 to 6,000, from
3,000 to 5,500,
from 3,000 to 5,000, from 3,000 to 4,500, from 3,000 to 4,000, from 3,000 to
3,500, from 4,000
to 30,000, from 4,000 to 25,000, from 4,000 to 20,000, from 4,000 to 15,000,
from 4,000 to
10,000, from 4,000 to 9,500, from 4,000 to 9,000, from 4,000 to 8,500, from
4,000 to 8,000,
from 4,000 to 7,500, from 4,000 to 7,000, from 4,000 to 6,500, from 4,000 to
6,000, from 4,000
to 5,500, from 4,000 to 5,000, from 4,000 to 4,500, from 5,000 to 30,000, from
5,000 to 25,000,
from 5,000 to 20,000, from 5,000 to 15,000, from 5,000 to 10,000, from 5,000
to 9,500, from
5,000 to 9,000, from 5,000 to 8,500, from 5,000 to 8,000, from 5,000 to 7,500,
from 5,000 to
7,000, from 5,000 to 6,500, from 5,000 to 6,000, from 5,000 to 5,500, from
6,000 to 30,000,
from 6,000 to 25,000, from 6,000 to 20,000, from 6,000 to 15,000, from 6,000
to 10,000, from
6,000 to 9,500, from 6,000 to 9,000, from 6,000 to 8,500, from 6,000 to 8,000,
from 6,000 to
7,500, from 6,000 to 7,000, from 6,000 to 6,500, from 7,000 to 30,000, from
7,000 to 25,000,
from 7,000 to 20,000, from 7,000 to 15,000, from 7,000 to 10,000, from 7,000
to 9,500, from
7,000 to 9,000, from 7,000 to 8,500, from 7,000 to 8,000, from 7,000 to 7,500,
from 8,000 to
30,000, from 8,000 to 25,000, from 8,000 to 20,000, from 8,000 to 15,000, from
8,000 to 10,000,
from 8,000 to 9,500, from 8,000 to 9,000, from 8,000 to 8,500, from 9,000 to
30,000, from 9,000
to 25,000, from 9,000 to 20,000, from 9,000 to 15,000, from 9,000 to 10,000,
from 9,000 to
9,500, from 10,000 to 30,000, from 10,000 to 25,000, from 10,000 to 20,000,
from 10,000 to
15,000, from 15,000 to 30,000, from 15,000 to 25,000, from 15,000 to 20,000,
from 20,000 to
30,000, from 20,000 to 25,000, or from 25,000 to 30,000 particles per um2.
[0091] Depending on composition and/or final application for the aluminum
alloy products,
example particle diameters may range from 100 nm to 100 um. For example the
particle
diameters may range from 150 nm to 100 um, from 200 nm to 100 um, from 300 nm
to 100 um,
from 400 nm to 100 um, from 500 nm to 100 um, from 600 nm to 100 um, from 700
nm to 100
um, from 800 nm to 100 um, from 1 um to 100 um, from 5 um to 100 m, from 10
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um, from 15 um to 100 um, from 25 um to 100 um, from 50 um to 100 um, from 75
um to 100
um, from 150 nm to 75 um, from 200 nm to 75 um, from 300 nm to 75 um, from 400
nm to 75
um, from 500 nm to 75 um, from 600 nm to 75 um, from 700 nm to 75 um, from 800
nm to 75
um, from 1 um to 75 um, from 5 um to 75 um, from 10 um to 75 um, from 15 um to
75 um,
from 25 um to 75 um, from 50 um to 75 um, from 150 nm to 50 um, from 200 nm to
50 um,
from 300 nm to 50 um, from 400 nm to 50 um, from 500 nm to 50 um, from 600 nm
to 50 um,
from 700 nm to 50 um, from 800 nm to 50 um, from 1 um to 50 um, from 5 um to
50 um, from
um to 50 um, from 15 um to 50 um, from 25 um to 50 um, from 150 nm to 25 um,
from 200
nm to 25 um, from 300 nm to 25 um, from 400 nm to 25 um, from 500 nm to 25 um,
from 600
nm to 25 um, from 700 nm to 25 um, from 800 nm to 25 um, from 1 um to 25 um,
from 5 um to
25 um, from 10 um to 25 um, from 15 um to 25 um, from 150 nm to 15 um, from
200 nm to 15
um, from 300 nm to 15 um, from 400 nm to 15 um, from 500 nm to 15 um, from 600
nm to 15
um, from 700 nm to 15 um, from 800 nm to 15 um, from 1 um to 15 um, from 5 um
to 15 um,
from 10 um to 15 um, from 150 nm to 10 um, from 200 nm to 10 um, from 300 nm
to 10 um,
from 400 nm to 10 um, from 500 nm to 10 um, from 600 nm to 10 um, from 700 nm
to 10 um,
from 800 nm to 10 um, from 1 um to 10 um, from 5 um to 10 um, from 150 nm to 5
um, from
200 nm to 5 um, from 300 nm to 5 um, from 400 nm to 5 um, from 500 nm to 5 um,
from 600
nm to 5 um, from 700 nm to 5 um, from 800 nm to 5 um, from 800 nm to 5 um,
from 1 um to 5
um, from 150 nm to 1 um, from 200 nm to 1 um, from 300 nm to 1 um, from 400 nm
to 1 um,
from 500 nm to 1 um, from 600 nm to 1 um, from 700 nm to 1 um, from 800 nm to
1 um, from
150 nm to 800 nm, from 200 nm to 800 nm, from 300 nm to 800 nm, from 400 nm to
800 nm,
from 500 nm to 800 nm, from 600 nm to 800 nm, from 700 nm to 800 nm, from 150
nm to 700
nm, from 200 nm to 700 nm, from 300 nm to 700 nm, from 400 nm to 700 nm, from
500 nm to
700 nm, from 600 nm to 700 nm, from 150 nm to 600 nm, from 200 nm to 600 nm,
from 300 nm
to 600 nm, from 400 nm to 600 nm, from 500 nm to 600 nm, from 150 nm to 500
nm, from 200
nm to 500 nm, from 300 nm to 500 nm, from 400 nm to 500 nm, from 150 nm to 400
nm, from
200 nm to 400 nm, from 300 nm to 400 nm, from 150 nm to 300 nm, from 200 nm to
300 nm, or
from 150 nm to 200 nm.
[0092] These diameter ranges may optionally represent the diameters of 80
percent (or
more) of the particles, meaning that although some particles may have
diameters outside the
stated range, at least 80 percent of the particles will have diameters within
the stated range. In
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some cases, the diameter ranges may represent the diameter of 25 percent (or
more) of the
particles, 30 percent (or more) of the particles, 35 percent (or more) of the
particles, 40 percent
(or more) of the particles, 45 percent (or more) of the particles, 50 percent
(or more) of the
particles, 55 percent (or more) of the particles, 60 percent (or more) of the
particles, 65 percent
(or more) of the particles, 70 percent (or more) of the particles, 75 percent
(or more) of the
particles, 80 percent (or more) of the particles, 85 percent (or more) of the
particles, 90 percent
(or more) of the particles, 95 percent (or more) of the particles, 98 percent
(or more) of the
particles, or 100 percent (or more) of the particles.
[0093] To control the particle sizing and inter-particle spacing,
conditions during casting and
homogenization may be adjusted to control the size and density of particle
generation. In some
cases, the composition of the aluminum alloy may control particle generation.
Specifically,
adjustment of the composition prior to casting, for example, may be useful to
generate a
favorable amount of intermetallic particles and/or to control particle
diameters and inter-particle
spacing.
[0094] During casting processes, aluminum alloys containing iron and
manganese may
generate intermetallic particles comprising aluminum and one or more of iron
or manganese,
which may be referred to herein as Al-(Fe, Mn) intermetallic particles or 0-
phase intermetallic
particles, within the cast aluminum alloy product. When silicon is present,
intermetallic particles
comprising aluminum, silicon, and one or more of iron or manganese, also
referred to herein as
Al-(Fe, Mn)-Si intermetallic particles or a-phase intermetallic particles, may
also be generated.
Exemplary a-phase and 0-phase intermetallic particles may include
A115(Fe,Mn)35i2 and
A16(Fe,Mn), respectively. As some amounts of iron and silicon are generally
present in almost
all aluminum alloys, many aluminum alloys may include such intermetallic
particles upon
casting.
[0095] Each of these intermetallic particle types exhibits different
properties and contributes
in different ways to the structure of the aluminum alloy. For example, 0-phase
particles tend to
be larger and more blocky or geometric than a-phase particles, while a-phase
particles are harder
and tend to be smaller than 0-phase particles, in general. During hot and cold
rolling,
intermetallic particles may be broken, impacting their size, inter-particle
spacing, and density, for
example. During homogenization, heat treatment, and/or aging, components may
diffuse in and
out of intermetallic particles, changing their composition, structure, and/or
size.
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[0096] By adjusting the composition of the aluminum alloy, specifically the
iron and silicon
content, the type of intermetallic particles generated may be controlled and
in turn the particle
sizes may be controlled. For example, if the intermetallic particle
distribution in an aluminum
alloy is such that the aluminum alloy contains 99% a-phase intermetallic
particles and only 1%
0-phase intermetallic particles, then the aluminum alloy may generate overall
finer/smaller
particles. However, if the amount of a-phase intermetallic particles generated
is reduced and the
amount of 0-phase intermetallic particles generated is increased, then the
overall particle size for
the aluminum alloy may be larger. Moreover, when the particle volume fraction
is constant
while adjusting the particle size, inter-particle spacing, and relatedly
particle density, may be
controlled.
[0097] Specific aluminum alloys useful with the disclosed methods and
aluminum alloy
products may include those containing aluminum, iron, magnesium, manganese,
and silicon. By
using an increased ratio of iron to silicon, the disclosed aluminum alloy
products may
preferentially generate 0-phase intermetallic particles during processing or
may convert a-phase
intermetallic particles to 0-phase intermetallic particles during a
homogenization process. For
example, in some embodiments, aluminum alloys useful with the methods and
products
described herein may have a ratio of a wt. % of iron to a wt. % of silicon of
from 0.5 to 5Ø
Optionally, an aluminum alloy may have a ratio of a wt. % of iron to a wt. %
of silicon from 0
such as from 0.5 to 5, from 0.5 to 4.7, from 0.5 to 4.6, from 0.5 to 4.5, from
0.5 to 4.25, from 0.5
to 4.0, from 0.5 to 3.75, from 0.5 to 3.5, from 0.5 to 3.25, from 0.5 to 3.0,
from 0.5 to 2.75, from
0.5 to 2.5, from 0.5 to 2.0, from 0.5 to 1.8, from 0.5 to 1.5, from 0.5 to
1.1, from 0.5 to 1.0, from
1.0 to 5.0, from 1.0 to 4.7, from 1.0 to 4.6, from 1.0 to 4.5, from 1.0 to
4.25, from 1.0 to 4.0,
from 1.0 to 3.75, from 1.0 to 3.5, from 1.0 to 3.25, from 1.0 to 3.0, from 1.0
to 2.75, from 1.0 to
2.5, from 1.0 to 2.0, from 1.0 to 1.8, from 1.0 to 1.5, from 1.0 to 1.1, from
1.1 to 5.0, from 1.1 to
4.7, from 1.1 to 4.6, from 1.1 to 4.5, from 1.1 to 4.25, from 1.1 to 4.0, from
1.1 to 3.75, from 1.1
to 3.5, from 1.1 to 3.25, from 1.1 to 3.0, from 1.1 to 1.75, from 1.1 to 2.5,
from 1.1 to 2.0, from
1.1 to 1.8, from 1.1 to 1.5, from 1.5 to 5.0, from 1.5 to 4.7, from 1.5 to
4.6, from 1.5 to 4.5, from
1.5 to 4.25, from 1.5 to 4.0, from 1.5 to 3.75, from 1.5 to 3.5, from 1.5 to
3.25, from 1.5 to 3.0,
from 1.5 to 1.75, from 1.5 to 2.5, from 1.5 to 2.0, from 1.5 to 1.8, from 1.8
to 5.0, from 1.8 to
4.7, from 1.8 to 4.6, from 1.8 to 4.5, from 1.8 to 4.25, from 1.8 to 4.0, from
1.8 to 3.75, from 1.8
to 3.5, from 1.8 to 3.25, from 1.8 to 3.0, from 1.8 to 1.75, from 1.8 to 2.5,
from 1.8 to 2.0, from
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2.0 to 5.0, from 2.0 to 4.7, from 2.0 to 4.6, from 2.0 to 4.5, from 2.0 to
4.25, from 2.0 to 4.0,
from 2.0 to 3.75, from 2.0 to 3.5, from 2.0 to 3.25, from 2.0 to 3.0, from 2.0
to 2.75, from 2.0 to
2.5, from 3.0 to 5.0, from 3.0 to 4.5, from 3.0 to 4.0, from 3.0 to 3.75, from
3.0 to 3.5, from 4.0
to 5.0, from 4.0 to 4.7, from 4.0 to 4.6, from 4.0 to 4.5, or from 4.0 to
4.25. Such ratios may
allow a cast alloy product to preferentially form desirable amounts of a-phase
and 0-phase
intermetallic particles during or after casting, resulting in controlled inter-
particle spacing, and
particle sizing.
[0098] These iron to silicon ratios may preferentially form 0-phase
intermetallic particles and
a-phase intermetallic particles in desired ratios such to achieve a desirable
volume fraction of
each type of intermetallic particle within the aluminum alloy. For example,
the aluminum alloy
may have from 0.5% to 4.0% by volume of a-phase intermetallic particles and
from 0% to 2.0%
by volume of 0-phase intermetallic particles. In some cases, the ratio of the
volume percent of
the a-phase intermetallic particles to a volume percent of the 0-phase
intermetallic particles may
be from 0.6 to 1,000; 1 to 800; 10 to 750; 50 to 500; or 100 to 250. In
embodiments, the ratio of
a-phase intermetallic particles to a 0-phase intermetallic particles may be
based on the density of
intermetallic particles instead of the volume fraction. In such embodiments, a
favorable ratio of
a-phase intermetallic particle number density to a 0-phase intermetallic
particle number density
may be from 0.2 to 1,000. For example, the ratio of a-phase intermetallic
particle number
density to a 0-phase intermetallic particle number density may be from 0.2 to
1,000, 0.2 to 750,
0.25 to 500, 0.25 to 100, 0.25 to 50, 0.3 to 25, 0.3 to 10, or 0.3 to 3.
Compositions of Aluminum Alloys and Aluminum Alloy Products
[0099] The following Tables 1-3 provide alloy compositions (wt. %) for
aluminum alloys
according to some embodiments. Specifically, the provided compositions may be
useful in
generating aluminum alloy products having favorable inter-particle spacing
while maintaining
favorable particle size. As discussed above with reference to FIG. 1, there
may be a balance
between inter-particle spacing and particle size that provides for improved
product formability.
The following compositions may provide for aluminum alloys and aluminum alloy
products
having improved formability and permit use of high amounts of recycled source
content.
[0100] In some examples, an aluminum alloy as described herein may have the
following
elemental composition as provided in Table 1.
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Table 1
Element Weight Percentage (wt. %)
Fe 0.1 ¨ 1.0
Si 0.05 ¨ 0.8
Mn 0.2 ¨ 2.0
Mg 0.2 ¨ 2.0
Cu 0 ¨ 0.5
Zn 0 ¨ 0.5
Al Remainder
[0101] In some examples, the aluminum alloy may have the following
elemental
composition as provided in Table 2.
Table 2
Element Weight Percentage (wt. %)
Fe 0.2 ¨ 0.8
Si 0.1 ¨ 0.7
Mn 0.6 ¨ 1.0
Mg 0.7 ¨ 1.0
Cu 0 ¨ 0.25
Zn 0 ¨ 0.2
Ti 0 ¨ 0.1
Cr 0 ¨ 0.1
Zr 0 ¨ 0.1
V 0 ¨ 0.1
Al Remainder
[0102] In some examples, the alloy may have the following elemental
composition as
provided in Table 3.
Table 3
Element Weight Percentage (wt. %)

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Fe 0.3 - 0.7
Si 0.15 - 0.5
Mn 0.8 - 1.4
Mg 0.9 - 1.1
Cu 0.1 - 0.2
Zn 0 - 0.15
Ti 0 - 0.08
Cr 0 - 0.05
Zr 0 - 0.05
V 0 - 0.05
Al Remainder
[0103] In some examples, the alloy may have the following elemental
composition as
provided in Table 4.
Table 4
Element Weight Percentage (wt. %)
Fe 0 - 0.7
Si 0.25 - 0.7
Mn 0.8 - 1.3
Mg 0.8 - 1.4
Cu 0 - 0.25
Zn 0 - 0.25
Ti 0 - 0.08
Cr 0 - 0.05
Zr 0 - 0.05
V 0 - 0.05
Al Remainder
[0104] In some examples, the alloys described herein may also include iron
(Fe) in an
amount of from 0.1% to 1.0% (e.g., from 0.20% to 0.8% or from 0.3% to 0.7%)
based on the
total weight of the alloy. For example, the alloy may include 0.10%, 0.11%,
0.12%, 0.13%,
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0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%,
0.25%,
0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%,
0.37%,
0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%,
0.49%,
0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%,
0.61%,
0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%,
0.73%,
0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%,
0.85%,
0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%,
0.97%,
0.98%, 0.99%, or 1.0% iron. All are expressed in wt. %.
[0105] In some examples, the alloys described herein may include silicon
(Si) in an amount
of from 0.05% to 0.80% (e.g., from 0.1% to 0.7% or from 0.15% to 0.5%) based
on the total
weight of the alloy. For example, the alloy may 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%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%,
0.45%,
0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%,
0.57%,
0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%,
0.69%,
0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, or 0.80%
silicon.
All are expressed in wt. %.
[0106] In some examples, the alloys described herein may include manganese
(Mn) in an
amount of from 0.2% to 2.0% (e.g., from 0.6% to 1.0% or from 0.8% to 1.4%)
based on the total
weight of the alloy. For example, the alloy may include 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%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%,
0.60%,
0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%,
0.72%,
0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%,
0.84%,
0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%,
0.96%,
0.97%, 0.98%, 0.99%, 1.0%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%,
1.17%,
1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%,
1.29%,
1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%,
1.41%,
1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, 1.50%, 1.51%, 1.52%,
1.53%,
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1.54%, 1.55%, 1.56%, 1.57%, 1.58%, 1.59%, 1.60%, 1.61%, 1.62%, 1.63%, 1.64%,
1.65%,
1.66%, 1.67%, 1.68%, 1.69%, 1.70%, 1.71%, 1.72%, 1.73%, 1.74%, 1.75%, 1.76%,
1.77%,
1.78%, 1.79%, 1.80%, 1.81%, 1.82%, 1.83%, 1.84%, 1.85%, 1.86%, 1.87%, 1.88%,
1.89%,
1.90%, 1.91%, 1.92%, 1.93%, 1.94%, 1.95%, 1.96%, 1.97%, 1.98%, 1.99%, or 2.0%
manganese.
In some cases, manganese may not be present in the alloy (i.e., 0%). All are
expressed in wt. %.
[0107] In some examples, the alloys described herein may include magnesium
(Mg) in an
amount of from 0.2% to 2.0% (e.g., from 0.7% to 1.0% or from 0.9% to 1.1%)
based on the total
weight of the alloy. For example, the alloy may include 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%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%,
0.60%,
0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%,
0.72%,
0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%,
0.84%,
0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%,
0.96%,
0.97%, 0.98%, 0.99%, 1.0%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%,
1.17%,
1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%,
1.29%,
1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%,
1.41%,
1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, 1.50%, 1.51%, 1.52%,
1.53%,
1.54%, 1.55%, 1.56%, 1.57%, 1.58%, 1.59%, 1.60%, 1.61%, 1.62%, 1.63%, 1.64%,
1.65%,
1.66%, 1.67%, 1.68%, 1.69%, 1.70%, 1.71%, 1.72%, 1.73%, 1.74%, 1.75%, 1.76%,
1.77%,
1.78%, 1.79%, 1.80%, 1.81%, 1.82%, 1.83%, 1.84%, 1.85%, 1.86%, 1.87%, 1.88%,
1.89%,
1.90%, 1.91%, 1.92%, 1.93%, 1.94%, 1.95%, 1.96%, 1.97%, 1.98%, 1.99%, or 2.0%
magnesium. All are expressed in wt. %.
[0108] In some examples, the alloys described may include copper (Cu) in an
amount of up
to 0.5% (e.g., from 0% to 0.25% or from 0.1% to 0.2%) based on the total
weight of the alloy.
For example, the alloy may include 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%,
0.30%, 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% copper. In
some cases,
copper is not present in the alloy (i.e., 0%). All are expressed in wt. %.
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[0109] In some examples, the alloys described herein may include zinc (Zn)
in an amount of
up to 0.50% (e.g., from 0% to 0.2% or from 0% to 1.5%) based on the total
weight of the alloy.
For example, the alloy may include 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%,
0.30%, 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% zinc. In some
cases, zinc
is not present in the alloy (i.e., 0%). All are expressed in wt. %.
[0110] In some examples, the alloys described herein may include titanium
(Ti) in an amount
of up to 0.10% (e.g., from 0.001% to 0.10%, from 0% to 0.05%, from 0.001% to
0.05%, or from
0.003% to 0.08%) based on the total weight of the alloy. For example, the
alloy may include
0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%,
0.010%, 0.011%
0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.020%,
0.021%,
0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%, 0.031%,
0.032%,
0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.041% 0.042%,
0.043%,
0.044%, 0.045%, 0.046%, 0.047%, 0.048%, 0.049%, 0.05%, 0.055%, 0.06%, 0.065%,
0.07%,
0.075%, 0.08%, 0.085%, 0.09%, 0.095%, or 0.1% titanium. In some cases,
titanium may not be
present in the alloy (i.e., 0%). All are expressed in wt. %.
[0111] In some examples, the alloys described herein may include chromium
(Cr) in an
amount of up to 0.10% (e.g., from 0.001% to 0.10%, from 0% to 0.05%, from
0.001% to 0.05%,
or from 0.003% to 0.08%) based on the total weight of the alloy. For example,
the alloy may
include 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%,
0.009%, 0.010%,
0.011% 0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.020%,
0.021%
0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%,0.03%, 0.031%
0.032%,
0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.041% 0.042%,
0.043%,
0.044%, 0.045%, 0.046%, 0.047%, 0.048%, 0.049%, 0.05%, 0.055%, 0.06%, 0.065%,
0.07%,
0.075%, 0.08%, 0.085%, 0.09%, 0.095%, or 0.10% chromium. In some cases,
chromium may
not be present in the alloy (i.e., 0%). All are expressed in wt. %.
[0112] In some examples, the alloys described herein may include zirconium
(Zr) in an
amount of up to 0.10% (e.g., from 0.001% to 0.10%, from 0% to 0.05%, from
0.001% to 0.05%,
or from 0.003% to 0.08%) based on the total weight of the alloy. For example,
the alloy may
include 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%,
0.009%, 0.010%,
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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%, 0.03%,
0.031%,
0.032%, 0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.041%,
0.042%,
0.043%, 0.044%, 0.045%, 0.046%, 0.047%, 0.048%, 0.049%, 0.05%, 0.055%, 0.06%,
0.065%,
0.07%, 0.075%, 0.08%, 0.085%, 0.09%, 0.095%, or 0.10% Zr. In other examples,
the alloys
may include zirconium in an amount less than 0.05% (e.g., 0.04%, 0.03%, 0.02%,
or 0.01%)
based on the total weight of the alloy. In some cases, zirconium may not be
present in the alloy
(i.e., 0%). All are expressed in wt. %.
[0113] In some examples, the alloys described herein may include vanadium
(V) in an
amount of up to 0.10% (e.g., from 0.001% to 0.10%, from 0% to 0.05%, from
0.001% to 0.05%,
or from 0.003% to 0.08%) based on the total weight of the alloy. For example,
the alloy may
include 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%,
0.009%, 0.010%,
0.011%, 0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%,
0.020%,
0.021%, 0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%,
0.031%,
0.032%, 0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.041%,
0.042%,
0.043%, 0.044%, 0.045%, 0.046%, 0.047%, 0.048%, 0.049%, 0.05%, 0.055%, 0.06%,
0.065%,
0.07%, 0.075%, 0.08%, 0.085%, 0.09%, 0.095%, or 0.10% vanadium. In other
examples, the
alloys may include vanadium in an amount less than 0.05% (e.g., 0.04%, 0.03%,
0.02%, or
0.01%) based on the total weight of the alloy. In some cases, vanadium may not
be present in
the alloy (i.e., 0%). All are expressed in wt. %.
[0114] In some examples, the alloys described herein may include one or
more rare earth
elements (i.e., one or more of scandium (Sc), yttrium (Y), lanthanum (La),
cerium (Ce),
praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium
(Eu),
gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er),
thulium (Tm),
ytterbium (Yb), and lutetium (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 alloy may 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 of the rare earth elements. All are expressed
in wt. %.
[0115] In some examples, the alloys described herein may include one or
more of
molybdenum (Mo), niobium (Nb), beryllium (Be), boron (B), cobalt (Co), Tin
(Sn), strontium
(Sr), vanadium (V), indium (In), hafnium (Hf), silver (Ag), and nickel (Ni) in
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0.20% (e.g., from 0.01% to 0.20% or from 0.05% to 0.15%) based on the total
weight of the
alloy. For example, the alloy may 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%, or 0.20% of one or
more of
molybdenum (Mo), niobium (Nb), beryllium (Be), boron (B), cobalt (Co), tin
(Sn), strontium
(Sr), vanadium (V), indium (In), hafnium (Hf), silver (Ag), and nickel (Ni).
All are expressed in
wt. %.
[0116] Optionally, the alloy compositions described herein may 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 gallium (Ga), calcium (Ca), bismuth (Bi), sodium (Na), lead (Pb),
or combinations
thereof. Accordingly, gallium, calcium, bismuth, sodium, or lead 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. The sum of all impurities may not exceed 0.15% (e.g., 0.10%). All
expressed in wt. %.
The remaining percentage of the alloy may be aluminum.
[0117] Incidental elements, such as grain refiners and deoxidizers, or
other additives may be
present in the aluminum alloys and aluminum alloy products and may add other
characteristics
on their own without departing from or significantly altering the aluminum
alloys and products
described herein or the characteristics of the aluminum alloys or products
described herein.
[0118] 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. In
some cases, iron and silicon may not be indicated as impurities. For example,
the amounts of
iron and silicon may be actively controlled to effect certain properties in
the alloy.
Methods of Producing Aluminum Alloys and Aluminum Alloy Products
[0119] FIG. 4 provides an overview of an example method of making an
aluminum alloy
product. The method of FIG. 4 begins at step 405, where an aluminum alloy 406
may be cast to
create a cast aluminum alloy product 407, such as an ingot or other cast
product. At step 410, the
cast aluminum alloy product 407 may be homogenized to generate a homogenized
aluminum
alloy product 411. At step 415, the homogenized aluminum alloy product 411 may
be subjected
to one or more hot rolling passes and/or one or more cold rolling passes to
form a rolled
aluminum alloy product 412, which may correspond to an aluminum alloy article,
such as an
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aluminum alloy plate, an aluminum alloy shate, or an aluminum alloy sheet.
Optionally, the
rolled aluminum alloy product 412 may be subjected to one or more forming or
stamping
processes to form an aluminum alloy article.
[0120] The aluminum alloys described herein may be cast using any suitable
casting method.
As a few non-limiting examples, the casting process may include a direct chill
(DC) casting
process or a continuous casting (CC) process. For example, FIG. 4 may depict a
schematic
illustration of a DC casting process at 405. A continuous casting system may
be used instead,
which may 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 may have an end opening from which
molten metal
can exit the molten metal injector and be injected into the casting cavity.
[0121] A cast aluminum alloy product, such as a cast ingot or other cast
product, may be
processed by any suitable means. Optionally, the processing steps may be used
to prepare
sheets. Example processing steps include, but are not limited to,
homogenization, hot rolling,
cold rolling, annealing, solution heat treatment, and pre-aging.
[0122] FIG. 5 provides a plot showing temperature of a cast aluminum alloy
product
according to the present disclosure as a function of time during a
homogenization process
according to some examples. During homogenization, the cast aluminum alloy
product may be
heated to a homogenization temperature (HT1). Heating for the homogenization
step may take
place from ambient conditions, room temperature (RT as shown in FIG. 5), or a
higher
temperature, and may occur at any suitable heating rate. In some embodiments,
a heating rate of
from about 10 C/hour to about 100 C/hour may be used. Example heating rates
may be from
20 C/hour to 90 C/hour, from 30 C/hour to 80 C/hour, from 40 C/hour to 70
C/hour, from
50 C/hour to 60 C/hour, about 10 C/hour, 20 C/hour, 30 C/hour, 40
C/hour, 50 C/hour, 60
C/hour, 70 C/hour, 80 C/hour, 90 C/hour, or 100 C/hour. The time duration
for the heating
process is illustrated in FIG. 5 as tR, running from time ¨tR to time 0.
[0123] The aluminum alloy product may be heated to a homogenization
temperature (HT1)
ranging from about 500 C to about 650 C. Example homogenization temperatures
(HT1)
include from about 550 C to about 615 C, from about 570 C to about 610 C,
from about 580
C to about 605 C, from about 590 C to about 600 C, about 500 C, 510 C,
520 C, 530 C,
540 C, 550 C, 560 C, 570 C, 580 C, 585 C, 590 C, 595 C, 600 C, 605
C, 610 C, 615
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C, or 620 C. As described in more detail herein, higher homogenization
temperatures may be
useful for controlling a size, distribution, concentration, and/or composition
of intermetallic
particles present in the aluminum alloy, so homogenization temperatures of
from about 585 C to
about 615 C may be desirable.
[0124] In some embodiments, higher homogenization temperatures may be
useful for
controlling a size, inter-particle spacing, distribution, concentration,
and/or composition of
intermetallic particles present in the aluminum alloy, so homogenization
temperatures of from
about 570 C to about 620 C may be desirable. In some embodiments, a
homogenization
temperature from about 585 C to about 615 C may be desirable. Optionally,
the
homogenization temperature may be within 25 C of a solidus temperature of the
aluminum
alloy.
[0125] The heated cast aluminum alloy product may then be allowed to soak
(i.e., held at the
indicated homogenization temperature) for a period of time. The time duration
for soaking
shown in FIG 5 is ti, which runs from time 0 to time ti. In some embodiments,
homogenization
may take place in an inert atmosphere, a reduced oxygen atmosphere, an oxygen-
free
atmosphere, or in air. In some examples, the total time for the homogenization
step, including
the heating and soaking phases, may be up to or greater than 12 hours or 32
hours. Optionally,
the soaking phase can be longer, even up to 36 hours. Long duration soaking of
over 12 hours or
over 24 hours may be useful, in embodiments, for controlling a size, inter-
particle spacing,
distribution, concentration, density, and/or composition of intermetallic
particles present in the
aluminum alloy.
[0126] Following the soaking phase, the homogenized aluminum alloy product
may have its
temperature reduced, such as by an active or passive cooling process.
Optionally, the
homogenized aluminum alloy may have its temperature reduced to room
temperature. Cooling
may take place at any suitable cooling rate. Example cooling rates include
heating rates of from
about 10 C/hour to about 50 C/hour, such as about 10 C/hour, 20 C/hour, 30
C/hour, 40
C/hour, or 50 C/hour. Optionally, the homogenized aluminum alloy product may
proceed
directly to hot rolling without being cooled to room temperature.
[0127] In some cases, the homogenization step includes multiple processes.
As illustrated in
FIG. 5, the homogenization step optionally includes heating the product to a
first
homogenization temperature (HT1), soaking at or about the first homogenization
temperature for
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a first time duration (ti), followed by cooling to a second homogenization
temperature (HT2), and
soaking at or about the second homogenization temperature for a second time
duration, shown in
FIG. 5 as t2-ti. For example, the aluminum alloy product may be cooled after
the first soak to a
second homogenization temperature of from 500 C to 600 C, such as about 500
C, 505 C,
510 C, 515 C, 520 C, 525 C, 530 C, 535 C, 540 C, 545 C, 550 C, 555
C, 560 C, 565
C, 570 C, 575 C, 580 C, 585 C, 590 C, or 595 C. The aluminum alloy
product may be
held at the second homogenization temperature for a second time duration of
from about 1 hours
to about 24 hours.
[0128] Following the homogenization step, a hot rolling step may be
performed. Optionally,
hot rolling may occur immediately after homogenization (i.e., without cooling
to room
temperature). In other embodiments, prior to the start of hot rolling, the
homogenized product
may be allowed to cool to a temperature of from 100 C to 500 C. For example,
the
homogenized product may be allowed to cool to a temperature of from 100 C to
500 C, from
250 C to 450 C, from 300 C to 450 C, from 325 C to 425 C or from 350 C to
400 C. The
product may then be hot rolled at a temperature between 200 C to 600 C to
form a hot rolled
plate, a hot rolled shate, or a hot rolled sheet having a gauge from 0.5 mm to
200 mm (e.g., 1
mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25
mm, 30
mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85
mm,
90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm,
180
mm, 190 mm, 200 mm, or anywhere in between). For example, the homogenized
product may
be hot rolled at a temperature to a thickness from 1 mm to 8 mm. During hot
rolling,
temperatures and other operating parameters may be controlled so that the exit
temperature of the
hot rolled product upon exit from the hot rolling mill is no more than about
500 C, no more than
about 450 C, no more than about 300 C, or no more than about 200 C. In some
cases, the exit
temperature of the hot rolled product may be from 100 C to 500 C, or from
200 C to 400 C.
[0129] In some cases, cast, homogenized, or hot rolled products may be cold
rolled using
cold rolling mills and technology into a sheet. The cold rolled sheet may have
a gauge from
about 0.10 mm to about 0.50 mm, from about 0.15 mm to about 0.3 mm, from about
0.5 mm to
about 10 mm or from about 0.7 mm to about 6.5 mm. Optionally, the cold rolled
sheet may have
a gauge of about 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0
mm, 4.5 mm,
5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5
mm, or 10.0
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mm. The cold rolling may be performed to result in a final gauge thickness
that represents a
gauge reduction of up to about 95% (e.g., up to 10%, up to 20%, up to 30%, up
to 40%, up to
50%, up to 60%, up to 70%, up to 80%, up to 85%, up to 90%, or up to 95%
reduction). During
cold rolling, temperatures and other operating parameters may be controlled so
that the exit
temperature of the cold rolled product upon exit from the cold rolling mill is
no more than about
300 C, no more than about 250 C, no more than about 200 C, or no more than
about 100 C.
In some cases, the exit temperature of the cold rolled product may be from 50
C to 250 C or
from 100 C to 200 C.
[0130] Optionally, an interannealing step may be performed after the cold
rolling step or in
between multiple cold rolling steps. The interannealing step may be performed
at a temperature
of from about 300 C to about 450 C (e.g., about 310 C, 320 C, 330 C, 340
C, 350 C, 360
C, 370 C, 380 C, 390 C, 400 C, 410 C, 420 C, 430 C, 440 C, or 450 C).
In some cases,
the interannealing step comprises multiple processes. In some non-limiting
examples, the
interannealing step may include heating the plate, shate, or sheet to a first
temperature for a first
period of time followed by heating to a second temperature for a second period
of time. For
example, the plate, shate or sheet may be heated to about 410 C for about 1
hour and then
heated to about 330 C for about 2 hours.
[0131] The cast, homogenized, or hot rolled alloy products described herein
may also be
used to make products in the form of plates or other suitable products. For
example, plates
including the products as described herein can be prepared by processing an
ingot in a
homogenization step or casting a product in a continuous caster followed by
homogenization and
subsequently hot rolling the homogenized product. In the hot rolling step, the
homogenized
product can be hot rolled to a 200 mm thick gauge or less (e.g., from about 10
mm to about 200
mm). For example, a homogenized aluminum alloy product can be hot rolled to a
plate having a
final gauge thickness of about 10 mm to about 175 mm, about 15 mm to about 150
mm, about 20
mm to about 125 mm, about 25 mm to about 100 mm, about 30 mm to about 75 mm,
or about 35
mm to about 50 mm.
[0132] Monolithic as well as non-monolithic, such as roll-bonded materials,
cladded alloys,
clad layers, composite materials, such as but not limited to carbon fiber-
containing materials, or
various other materials are also useful with the methods and aluminum alloys
and aluminum
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[0133] FIG. 6 provides a method 600 of making an aluminum alloy having
favorable particle
density and inter-particle spacing between the particles according to an
embodiment as disclosed
herein. At block 610, a cast aluminum alloy product may be prepared. A cast
aluminum alloy
product may comprise an aluminum alloy including aluminum, iron, magnesium,
manganese,
and silicon, for example. The cast aluminum alloy product may include an
aluminum alloy
having an elemental composition as provided herein, specifically those
provided at Tables 1-3.
Preparing the cast aluminum alloy product may include preparing a molten
aluminum alloy and
casting the molten aluminum alloy.
[0134] The source aluminum alloy(s) for the aluminum alloy products
prepared according to
the methods and techniques described herein may correspond to the same series
aluminum alloy
or a mixture of different series aluminum alloys. Optionally, preparing the
cast aluminum alloy
product may comprise preparing a molten 3xxx series aluminum alloy and casting
the molten
3xxx series aluminum alloy. Optionally, preparing the molten 3xxx series
aluminum alloy may
comprise melting both a 3xxx series source aluminum alloy and a 5xxx series
source aluminum
alloy. In some cases, one or more of the source aluminum alloys may be from a
recycled source
content. In some embodiments, aluminum alloys including a higher percentage of
iron may be
useful for achieving a target iron to silicon ratio. For example, preparing
the molten aluminum
alloy optionally may further comprise melting a 4xxx series aluminum alloy or
a 6xxx series
aluminum alloy along with a 3xxx series source aluminum alloy and/or a 5xxx
series source
aluminum alloy.
[0135] At block 620, the cast aluminum alloy product may be homogenized.
Optionally,
homogenizing may include heating the cast aluminum alloy product to a
homogenization
temperature, such as a homogenization temperature that is between 500 C and
650 C, and
soaking the cast aluminum alloy product at the homogenization temperature for
a time duration
between 0.1 hours and 36 hours, for example. During soaking, a structure of
the aluminum alloy
may change. As an example, during soaking, silicon from the aluminum alloy may
diffuse into
and transform at least a fraction of the 0-phase intermetallic particles into
a-phase intermetallic
particles. As an example, during soaking, iron from the aluminum alloy may
diffuse into and
transform at least a fraction of the a-phase intermetallic particles into 0-
phase intermetallic
particles. As another example, during the soaking, iron may diffuse out of the
0-phase
intermetallic particles and be optionally replaced by manganese. As another
example, during the
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soaking, iron may diffuse out of the 0-phase intermetallic particles and into
dispersoids present
within the cast aluminum alloy product.
[0136] In embodiments where the aluminum alloy includes a 3xxx series
aluminum alloy,
during the soaking, silicon from the 3xxx series aluminum alloy may diffuse
into and transform
at least a fraction of the 0-phase intermetallic particles into a-phase
intermetallic particles.
Optionally, during these embodiments, during the soaking, iron diffuses out of
the 0-phase
intermetallic particles and is replaced by manganese. In some embodiments,
when the iron
diffuses out of the 0-phase intermetallic particles, the iron may combine with
dispersoids present
within the cast aluminum alloy product to form a-phase intermetallic
particles. The dispersoids
may include manganese.
[0137] By controlling the homogenization temperatures and duration, the
nature of the
intermetallic particles may change. For example, during the soaking, an
average size of the f3-
phase intermetallic particles may increase or decrease. For example, an
average size of the f3-
phase intermetallic particles may decrease as compared to an average size of
the 0-phase
intermetallic particles prior to soaking. Optionally, a number density of the
0-phase intermetallic
particles in the cast aluminum alloy product may increase or decrease.
Optionally, prior to
homogenizing, a ratio of an a-phase intermetallic particle number density to a
0-phase
intermetallic particle number density in the cast aluminum alloy product is
between 0.3 and 3.
Optionally, after homogenizing, a ratio of an a-phase intermetallic particle
number density to a
0-phase intermetallic particle number density in the homogenized aluminum
alloy product may
be from 0.2 to 1000 or more (e.g., from 2 to 1000). In some cases, an amount
of the a-phase
intermetallic particles may be transformed into 0-phase intermetallic
particles during
homogenizing, such as 30% or more, 40% or more, 50% or more, 55% or more, 60%
or more,
65% or more, 70% or more, 80% or more, 90% or more, 95% or more, 96% or more,
97% or
more, 98% or more, 99% or more, 99.5% or more or up to 100%. In some cases, a
majority of
the a-phase intermetallic particles are transformed into 0-phase intermetallic
particles during
homogenizing.
[0138] In some embodiments, such as those in which the aluminum alloy
includes a 3xxx
series aluminum alloy, an amount of the 0-phase intermetallic particles may be
transformed into
a-phase intermetallic particles during homogenizing, in particular, during
soaking. For example,
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during soaking, approximately 30% to 100% of the 0-phase intermetallic
particles may be
transformed into a-phase intermetallic particles.
[0139] In some embodiments, multiple homogenization steps may be useful.
For example, a
secondary lower temperature homogenization after an initial higher
temperature, long duration
homogenization may be useful for preparing an aluminum alloy product, such as
for rolling or
other processing. A multiple-step homogenization process may include reducing
a temperature
of the homogenized aluminum alloy product to a second homogenization
temperature less than
the first homogenization temperature, and soaking the homogenized aluminum
alloy product at
the second homogenization temperature for a second time duration, such as a
second time
duration that is shorter than the time duration of the initial long-duration
soak. In some
embodiments, soaking the homogenized aluminum alloy product at the second
homogenization
temperature may control a surface quality or characteristic of the homogenized
aluminum alloy
product. Optionally, soaking the homogenized aluminum alloy product at the
second
homogenization temperature may bring a temperature of the homogenized aluminum
alloy
product to a temperature sufficient for a rolling process.
[0140] At block 640, the method 600 may optionally include subjecting the
homogenized
rolled aluminum alloy product to one or more rolling processes to produce a
rolled aluminum
alloy product. For example, the homogenized rolled aluminum alloy product may
be subjected
to one or more hot rolling processes at block 642. In some cases, the
homogenized rolled
aluminum alloy product may also be subjected to one or more cold rolling
processes at block
644. During the hot and cold rolling processes, intermetallic particles may be
broken, impacting
their size, distribution, and number density, for example.
[0141] Hot rolling the rolled aluminum alloy product at relatively high
temperatures, such as
above about 550 C, depending on the alloy, may encounter difficulties due to
roll sticking and
bite refusal. This may also result in grain boundary separation and surface
tearing, which can
enhance oxidation at the surface. Since the affinity of oxide formation is
higher at higher
temperatures, at least in part due to faster diffusion of solute elements
(e.g., magnesium (Mg),
silicon (Si), etc.,) on the surface, the new fresh surface that forms from
tearing may oxidize
promptly and often results in a non-uniform surface with an undesirable oxide
layer.
Advantageously, however, lowering the hot rolling exit temperature, such as to
a temperature
below about 550 C, for example from about 100 C to 500 C, may give more
control on roll
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bite with higher friction and reduce the tendency of the surface to stick,
tear, and oxidize. In
addition, the reduced diffusivity of solute elements at lower temperatures can
result in a more
uniform surface layer than at higher temperatures.
[0142] Similarly, controlling the cold rolling exit temperature may also
allow for an
improved aluminum alloy product. Exit temperature from a cold rolling process
from about 100
C to 200 C may allow for the rolled aluminum alloy product to be rolled to a
thickness of 0.15
to 0.30 mm without sticking, tearing, or breakage.
Methods of Using the Disclosed Aluminum Alloy Products
[0143] The aluminum alloy products described herein can be used in a
variety of
applications. In specific embodiments, the aluminum alloy products described
herein are useful
for beverage container body stock, such as aluminum can body stock or aluminum
bottle body
stock. Aluminum alloy sheets may be subjected to a blanking process in which
discs of the
aluminum alloy are cut from an aluminum alloy sheet. The discs may be
subjected to one or
more drawing, ironing, necking or other forming processes to form a suitable
beverage container
body or preform.
[0144] Other applications may be suitable for some of the aluminum alloy
products
described herein. For example, the disclosed aluminum alloy products can be
used to prepare
automotive parts, aircraft or railway vehicle panels, architectural panels,
building products, and
the like. In some examples, cookware, foils, formed containers, bottle caps,
and packaging (e.g.,
food packaging) may be made using the disclosed aluminum alloy products.
[0145] The aluminum alloy products and methods described herein can also be
used in
electronics applications. For example, the aluminum alloy products and methods
described
herein can be used to prepare housings for electronic devices, including
mobile phones and tablet
computers. In some examples, the aluminum alloy products can be used to
prepare housings for
the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis,
and other portable
electronics.
[0146] The examples disclosed herein will serve to further illustrate
aspects of the invention
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
skilled in the art without departing from the spirit of the invention. The
examples and
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embodiments described herein may also make use of conventional procedures,
unless otherwise
stated. Some of the procedures are described herein for illustrative purposes.
EXAMPLE
[0147] The following Table 1 provides alloying solute compositions (wt. %)
of two example
3104 aluminum alloys, Alloy A and Alloy B. Alloy A is slightly enriched in
solute as compared
to Alloy B. A ratio of silicon to iron in Alloy A is about 0.60, while in
Alloy B the ratio is about
0.56. The solidus temperatures of the alloys were calculated to be within 2 C
of one another,
indicating that the samples are expected to have similar melting and physical
properties. The
solvus temperature for Mg2Si for Alloy A was calculated to be slightly higher
than for Alloy B.
Four sample ingots of each of Alloy A and Alloy B were prepared and used to
evaluate the effect
of different homogenization regimes on intermetallic particles present in the
alloys. The as-cast
samples had a gauge of about 40 mm.
Si Fe Cu Mn Mg Cr
Solvus ( C) Solidus ( C)
Mg2Si
Alloy A 0.32 0.53 0.19 0.86 1.25 0.03 409 623
Alloy B 0.27 0.48 0.18 0.85 1.15 0.03 393 625
Table 1.
[0148] Predicted equilibrium phase diagrams for Alloy A and Alloy B were
determined and
are shown in FIG. 7A and FIG. 7B, respectively. Both alloys show similar
constituent phase
types at just below melting, which primarily includes a-phase particles
(ALPHA) and 0-phase
particles (e.g., Al6Mn or Al3Fe), though the Alloy A has a higher a to 0 ratio
than Alloy B, which
may be due to higher silicon and iron content in Alloy A.
[0149] Samples of Alloy A and two samples of Alloy B were subjected to a
heat-to-roll
(HTR) processing scheme, where the samples were heated at a slow rate of about
50 C/h to a
temperature of about 500 C. Other samples of Alloy A and other samples of
Alloy B were
subjected to a 2-stage (2STG) processing scheme, where the samples were heated
at a slow rate
of about 50 C/h to a temperature of about 600 C, held at this temperature
for about 24 hours,
and then cooled to about 560 C, where they were held for about 4 additional
hours.
[0150] Scanning electron micrograph (SEM) images under back-scattered
electron (B SE)
contrast were obtained of cross-sections of samples of the as-cast Alloy A and
Alloy B, as well

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as samples of Alloy A and Alloy B after the HTR or 2STG processing, in order
to evaluate the
particle distribution and microstructure of the samples. These images are
shown in FIG. 8. The
images show that, overall, the sizes of the particles in Alloy A are smaller
than the particles in
Alloy B. After the HTR processing, no changes in the constituent particles
were observed for
either Alloy A or Alloy B. The as-cast and HTR processed samples showed a mix
of a-phase
particles and 0-phase particles. After the 2STG processing, however, only a-
phase particles
were observed in the microstructures, with a more fine particle size
distribution. In some cases,
the 2STG processing transformed the structure to a more porous character.
[0151] Samples of the as-cast Alloy A and Alloy B, as well as samples of
Alloy A and Alloy
B after the HTR or 2STG processing, were subjected to electrical conductivity
measurements. A
bar chart showing the results of the measurements in terms of a percent of the
International
Annealed Copper Standard (IACS) is depicted in FIG. 9. Overall, Alloy A shows
higher
resistivity than Alloy B, which may be due to a higher solute level in Alloy
A. The conductivity
of all processed samples was observed to be higher than the respective as-cast
samples, which
may be due to precipitation of manganese out of the solid solution and
formation of dispersoids.
A noticeably smaller conductivity was observed for the 2STG processed samples
as compared to
the HTR samples, which may be due to a higher solubility of manganese in the
2STG processed
samples because of higher processing temperatures can allow manganese present
in the
dispersoids to dissolve back into the metal solid solution.
[0152] To further characterize the properties of the different alloys,
samples of Alloy A and
Alloy B were subjected to rolling processes. For samples of the alloys
subjected to HTR
processing, immediately after the HTR processing, samples of Alloy A and Alloy
B were
subjected to a hot rolling operation to a gauge of about 7.0 mm,
recrystallized, and then
subjected to a cold rolling operation to a gauge of about 1.0 mm to form hard
H19 temper
products. Recrystallizing may optionally be achieved by coiling the hot-rolled
product and
cooling the coil or may be achieved by annealing the hot-rolled product. Some
of the cold rolled
H19 temper product samples of Alloy A and the cold rolled H19 temper product
samples of
Alloy B were then annealed at 350 C for 1 hour to generate soft 0 temper
products. The hard
H19 temper product samples are referred to as AHTR,H19 and BHTR,H19 and the
soft 0 temper
product samples are referred to as AHTR,0 and BHTR,O.
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[0153] Similarly, for samples of the alloys subjected to 2STG processing,
immediately after
the 2STG processing, heated and homogenized samples of Alloy A and Alloy B
were subjected
to a hot rolling operation to a gauge of about 7.0 mm, recrystallized, and
then subjected to a cold
rolling operation to a gauge of about 1.0 mm to form hard H19 temper products.
One of the cold
rolled H19 temper product samples of Alloy A and one of the cold rolled H19
temper product
samples of Alloy B were then annealed at 350 C for 1 hour to generate soft 0
temper products.
The hard H19 temper product samples are referred to as A2STG,H19 and B2STG,H19
and the soft 0
temper product samples are referred to as A2STG,0 and B2STG,O.
[0154] SEM images under BSE contrast were obtained in a plan view
configuration for the
AHTR,H19, BHTR,H19, A2STG,H19, and B2STG,H19 samples in order to evaluate the
particle distribution
and microstructure of the samples in the final gauge condition. These images
are shown in FIG.
10. Less dense and coarser particles were generally observed in Alloy B as
compared to Alloy
A. A decrease in the overall particle size is observed for the samples
subjected to the 2STG
processing as compared to the HTR processing. Additionally, in the samples
subjected to the
2STG processing, fine particles were noticed surrounding the coarser
particles, which may be
due to more breakup and/or spheroidization of the particles because of the
higher temperatures
encountered in the 2STG processing.
[0155] High resolution cross-sectional images of the AHTR,H19, BHTR,H19,
A2STG,H19, and
B2STG,H19 samples were obtained using a field emission gun scanning electron
microscope
(FEGSEM) to investigate the spatial distribution of dispersoids (e.g.,
manganese containing
dispersoids) in the final gauge samples. The obtained images are shown in FIG.
11, with the
dispersoids identified as white spots in the images. The dispersoids in the
samples subjected to
the HTR processing were numerous and very fine. In contrast, the dispersoids
in the samples
subjected to the 2STG processing were fewer in number density, but also more
coarse, again due
to the longer and higher temperatures of the 2STG processing, allowing for
more mobility and
time for iron atoms to be taken up and convert the dispersoids to a-phase
particles and/or for
constituent atoms to be taken up into and grow the dispersoids. Slightly
larger size dispersoids
can be seen in the Alloy A samples as compared to the Alloy B samples, which
may be
attributable to a slightly higher amount of solute in Alloy A as compared to
Alloy B.
[0156] SEM images obtained in a plan view configuration for the AHTR,H19,
BHTR,H19,
A2STG,H19, and B2STG,H19 samples were analyzed to identify particle size
distributions for various
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particulate components in the samples (by estimating particle area and size)
and plots showing
the results are shown in FIG. 12. In general, the Alloy A samples showed a
finer size
distribution for all particles as compared to the Alloy B samples. The samples
subjected to HTR
processing showed a significant fraction of particles identified in the
figures as Al(Fe,Mn),
which may correspond to 0-phase particles. In contrast, the samples subjected
to 2STG
processing showed little or none of these particles, and much higher
populations of a-phase
particles, indicating that the a-phase particles may be generated by
transforming 0-phase
particles during the prolonged homogenization of the 2STG processing.
[0157] Cross-sectional images of the AHTR,H19, BHTR,H19, A2STG,H19, and
B2STG,H19 samples
were obtained to observe the grain structure prior to recrystallization. The
images are shown in
FIG. 13. The grains show an elongated structure for all the samples, and black
spots on the grain
structures correspond to constituent particles, with the 2STG processed
samples showing finer
particle distributions, in correspondence with the plots of FIG. 12, with
overall greater numbers
of particles observed in the Alloy A samples as compared to the corresponding
Alloy B samples.
[0158] Cross-sectional images of the AHTR,O, BHTR,O, A2STG,O, and B2STG,0
samples were
obtained to observe the grain structure after recrystallization associated
with annealing, shown in
FIG. 14. The Alloy A samples show more equiaxed grains while the Alloy B
samples show
some elongated grains. Since the Alloy A samples had more particles overall
than the
corresponding Alloy B samples, particle stimulated nucleation may contribute
to the less
elongated grain structure in Alloy A samples. Comparing the HTR processed and
2STG
processed samples, more equiaxed grains were observed for the 2STG processed
samples, which
may be due to a larger number density of dispersoids present in the HTR
processed samples,
which may inhibit recrystallization by pinning at the grain boundaries.
[0159] Tensile properties in longitudinal cross-sections of the H19 and 0
temper samples
were measured, and the results are shown in FIG. 15A and FIG 15B. In the H19
temper, the
yield strength (YS) ultimate tensile strength (UTS), and ultimate elongation
(UE) of the Alloy A
samples was slightly greater than the Alloy B samples, while the total
elongation (TE) did not
show an overall alloy trend. A loss in strength and gain in elongation was
observed for the
2STG processed samples as compared to the HTR processed samples. Bendability
properties of
the H19 and 0 temper samples were also measured by performing wrap bend tests,
with the
results shown in FIG. 16A and FIG. 16B. Some bendability improvements were
observed for the
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2STG processed samples as compared to the HTR processed samples, meaning that
the 2STG
processed samples were able to withstand bending to a smaller radius to
thickness (r/t) than the
HTR processed samples.
[0160] Hole expansion tests were performed on both the H19 and 0 temper
samples, and the
results are shown in FIG. 13. The 2STG processed samples for both alloys
exhibited higher hole
expansion ratios than the HTR processed samples. The Alloy B samples also
exhibited higher
hole expansion ratios than the Alloy A samples. The H19 temper Alloy A sample
showed poor
hole expansion, which may be due to the presence of a large number density of
constituent
particles in the sample. The energy stored at the interface between the
particles and the matrix
may be very high for hard tempers and this energy may trigger initiation of
cracks followed by
coalescence and propagation to failure. In contrast, Alloy B contains less
constituent particles,
meaning less stored energy, and less susceptibility to cracking at the same
strains at which the
Alloy A samples would crack. For the softer temper material, the constituent
morphology may
be more influential than the number density of particles, as there is less
energy present at the
interface between the particles and the matrix. The 2STG processed samples
exhibited
spheroidical particles than HTR processed samples, which may allow the strains
to be more
evenly distributed around the particles than in the more needle-shaped
particles of the HTR
processed samples, which may result in concentration of strain and earlier
crack initiation.
ILLUSTRATIONS
[0161] As used below, any reference to a series of illustrations is to be
understood as a
reference to each of those examples disjunctively (e.g., "Illustrations 1-4"
is to be understood as
"Illustrations 1, 2, 3, or 4").
[0162] Illustration 1 is an aluminum alloy product comprising: an aluminum
alloy
comprising aluminum, iron, magnesium, manganese, and silicon, wherein a ratio
of an iron wt.
% in the aluminum alloy to a silicon wt. % in the aluminum alloy is from 0.5
to 5.0, and wherein
the aluminum alloy includes a plurality of particles including a-phase
intermetallic particles
comprising aluminum, silicon, and one or more of iron or manganese and fl-
phase intermetallic
particles comprising aluminum and one or more of iron or manganese; and
wherein the
aluminum alloy has a particle density for the plurality of particles of from 5
to 30,000 particles
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per i.tm2 and wherein the aluminum alloy has an inter-particle spacing for the
plurality of
particles of from 1 p.m to 25 p.m.
[0163] Illustration 2 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the plurality of particles has diameters of from 500 nm to 50 p.m.
[0164] Illustration 3 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the particle density is from 50 to 1,000 particles per i.tm2.
[0165] Illustration 4 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the aluminum alloy is from a recycled source.
[0166] Illustration 5 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the aluminum alloy comprises: from 0.1 wt. % to 1.0 wt. % iron, from
0.05 wt. % to 0.8
wt. % silicon, from 0.2 wt. % to 2.0 wt. % manganese, from 0.2 wt. % to 2.0
wt. % magnesium,
up to 0.5 wt. % copper, up to 0.05 wt. % zinc, and aluminum.
[0167] Illustration 6 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the aluminum alloy comprises up to 0.15 wt. % impurities.
[0168] Illustration 7 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the aluminum alloy comprises: from 0.2 wt. % to 0.8 wt. % iron, from
0.10 wt. % to 0.7
wt. % silicon, from 0.6 wt. % to 1.0 wt. % manganese, from 0.7 wt. % to 1.0
wt. % magnesium,
up to 0.25 wt. % copper, up to 0.2 wt. % zinc, up to 0.10 wt. % titanium, up
to 0.10 wt. %
chromium, up to 0.10 wt. % zirconium, up to 0.10 wt. % vanadium, and aluminum.
[0169] Illustration 8 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the aluminum alloy comprises: from 0.3 wt. % to 0.7 wt. % iron, from
0.15 wt. % to 0.5
wt. % silicon, from 0.8 wt. % to 1.2 wt. % manganese, from 0.9 wt. % to 1.2
wt. % magnesium,
from 0.1 wt. % to 0.2 wt. % copper, up to 0.15 wt. % zinc, up to 0.08 wt. %
titanium, up to 0.05
wt. % chromium, up to 0.05 wt. % zirconium, up to 0.05 wt. % vanadium, and
aluminum.
[0170] Illustration 9 is the aluminum alloy product of any previous or
subsequent illustration,
wherein the a-phase intermetallic particles comprise from 0.5% to 4.0% by
volume of the
aluminum alloy, and wherein the 0-phase intermetallic particles comprise from
0% to 2.0% by
volume of the aluminum alloy.
[0171] Illustration 10 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the a-phase intermetallic particles comprise
A115(Fe,Mn)3Si2, and wherein
the 0-phase intermetallic particles comprise A16(Fe,Mn).

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[0172] Illustration 11 is the aluminum alloy product of any previous or
subsequent
illustration, wherein a ratio of an a-phase intermetallic particle number
density to a 0-phase
intermetallic particle number density is from 0.2 to 1,000 or wherein a ratio
of a volume % of the
a-phase intermetallic particles to a volume % of the 0-phase intermetallic
particles is from 0.6 to
1,000.
[0173] Illustration 12 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the ratio of the a-phase intermetallic particle number
density to the 0-phase
intermetallic particle number density is from 0.3 to 3.
[0174] Illustration 13 is the aluminum alloy product of any previous or
subsequent
illustration, wherein 80 percent or more of the plurality of particles have an
inter-particle spacing
from 5 p.m to 15 m.
[0175] Illustration 14 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the plurality of particles comprise iron-containing
particles, wherein a
majority of the iron-containing particles have a diameter from 1 p.m to 40 m.
[0176] Illustration 15 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the iron-containing particles comprise from 1% to 4% of
a total volume of
the aluminum alloy.
[0177] Illustration 16 is the aluminum alloy product of any previous or
subsequent
illustration, further comprising manganese-containing dispersoids, wherein a
majority of the
manganese-containing dispersoids have a diameter of from 10 nm to 1.5 p.m.
[0178] Illustration 17 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the manganese-containing dispersoids comprise up to 1%
of a total volume
of the aluminum alloy.
[0179] Illustration 18 is a method of making an aluminum alloy product, the
method
comprising: preparing a cast aluminum alloy product comprising an aluminum
alloy, wherein the
aluminum alloy comprises aluminum, iron, magnesium, manganese, and silicon,
wherein a ratio
of a silicon wt. % in the aluminum alloy to an iron wt. % in the aluminum
alloy is from 0.5 to
1.0, and wherein the aluminum alloy includes a plurality of particles
including a-phase
intermetallic particles comprising aluminum, silicon, and one or more of iron
or manganese and
0-phase intermetallic particles comprising aluminum and one or more of iron or
manganese; and
homogenizing the cast aluminum alloy product to form a homogenized aluminum
alloy product
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by: heating the cast aluminum alloy product to a homogenization temperature
from 500 C to
650 C; and soaking the cast aluminum alloy product at the homogenization
temperature for a
time duration from 0.1 hours to 36 hours, and wherein the aluminum alloy
product has a particle
density for the plurality of particles of from 5 to 30,000 particles per i.tm2
and wherein the
aluminum alloy product has an inter-particle spacing for the plurality of
particles of from 1 p.m
to 25 p.m.
[0180] Illustration 19 is the method of any previous or subsequent
illustration, wherein the
time duration is from 0.5 to 10 hours.
[0181] Illustration 20 is the method of any previous or subsequent
illustration, wherein the
homogenization temperature is from 570 C to 620 C.
[0182] Illustration 21 is the method of any previous or subsequent
illustration, wherein the
homogenization temperature is within 25 C of a solidus temperature of the
aluminum alloy.
[0183] Illustration 22 is the method of any previous or subsequent
illustration, wherein,
during the soaking, a size of the 0-phase intermetallic particles decreases as
compared to a size
of the 0-phase intermetallic particles prior to the soaking.
[0184] Illustration 23 is the method of any previous or subsequent
illustration, wherein,
during the soaking, a number density of the 0-phase intermetallic particles in
the cast aluminum
alloy product decreases as compared to a number density of the 0-phase
intermetallic particles in
the cast aluminum alloy product prior to the soaking.
[0185] Illustration 24 is the method of any previous or subsequent
illustration, further
comprising subjecting the homogenized aluminum alloy product to one or more
rolling processes
to produce a rolled aluminum alloy product.
[0186] Illustration 25 is the method of any previous or subsequent
illustration, wherein the
one or more rolling processes comprise at least one of a hot rolling process
or a cold rolling
process.
[0187] Illustration 26 is the method of any previous or subsequent
illustration, wherein the
hot rolling process comprises an exit temperature of from 100 C to 500 C.
[0188] Illustration 27 is the method of any previous or subsequent
illustration, wherein the
exit temperature is from 200 C to 400 C.
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[0189] Illustration 28 is the method of any previous or subsequent
illustration, wherein the
rolled aluminum alloy product produced by the hot rolling process has a
thickness from 1 mm to
8 mm.
[0190] Illustration 29 is the method of any previous or subsequent
illustration, wherein the
cold rolling process comprises an exit temperature of from 50 C to 250 C.
[0191] Illustration 30 is the method of any previous or subsequent
illustration, wherein the
exit temperature is from 100 C to 200 C.
[0192] Illustration 31 is the method of any previous or subsequent
illustration, wherein the
rolled aluminum alloy product produced by the cold rolling process has a
thickness from 0.15
mm to 0.30 mm.
[0193] Illustration 32 is the method of any previous or subsequent
illustration, wherein the
plurality of particles comprises a particle diameter from 500 nm to 50 p.m.
[0194] Illustration 33 is the method of any previous or subsequent
illustration, wherein the
particle density is from 50 to 1,000 particles per i.tm2.
[0195] Illustration 34 is the method of any previous or subsequent
illustration, wherein the
aluminum alloy is from a recycled source.
[0196] Illustration 35 is the method of any previous or subsequent
illustration, wherein the
aluminum alloy comprises: from 0.1 wt. % to 1.0 wt. % iron, from 0.05 wt. % to
0.8 wt. %
silicon, from 0.2 wt. % to 2.0 wt. % manganese, from 0.2 wt. % to 2.0 wt. %
magnesium, up to
0.5 wt. % copper, up to 0.05 wt. % zinc, and aluminum.
[0197] Illustration 36 is the method of any previous or subsequent
illustration, wherein the
aluminum alloy comprises: from 0.2 wt. % to 0.8 wt. % iron, from 0.10 wt. % to
0.7 wt. %
silicon, from 0.6 wt. % to 1.0 wt. % manganese, from 0.7 wt. % to 1.0 wt. %
magnesium, up to
0.25 wt. % copper, up to 0.2 wt. % zinc, up to 0.10 wt. % titanium, up to 0.10
wt. % chromium,
up to 0.10 wt. % zirconium, up to 0.10 wt. % vanadium, and aluminum.
[0198] Illustration 37 is the method of any previous or subsequent
illustration, wherein the
aluminum alloy comprises: from 0.3 wt. % to 0.7 wt. % iron, from 0.15 wt. % to
0.5 wt. %
silicon, from 0.8 wt. % to 1.2 wt. % manganese, from 0.9 wt. % to 1.2 wt. %
magnesium, from
0.1 wt. % to 0.2 wt. % copper, up to 0.15 wt. % zinc, up to 0.08 wt. %
titanium, up to 0.05 wt. %
chromium, up to 0.05 wt. % zirconium, up to 0.05 wt. % vanadium, and aluminum.
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[0199] Illustration 38 is the method of any previous or subsequent
illustration, wherein the a-
phase intermetallic particles comprise from 0.5% to 4.0% by volume of the
aluminum alloy and
the 0-phase intermetallic particles comprise from 0 to 2.0% by volume of the
aluminum alloy.
[0200] Illustration 39 is the method of any previous or subsequent
illustration, wherein the a-
phase intermetallic particles comprise A115(Fe,Mn)3Si2, and wherein the 0-
phase intermetallic
particles comprise A16(Fe,Mn).
[0201] Illustration 40 is the method of any previous or subsequent
illustration, wherein a
ratio of an a-phase intermetallic particle number density to a 0-phase
intermetallic particle
number density is from 0.2 to 1,000 or wherein a ratio of a volume % of the a-
phase
intermetallic particles to a volume % of the 0-phase intermetallic particles
is from 0.6 to 1,000.
[0202] Illustration 41 is the method of any previous or subsequent
illustration, wherein the
ratio of an a-phase intermetallic particle number density to the 0-phase
intermetallic particle
number density is from 0.3 to 3.
[0203] Illustration 42 is the method of any previous or subsequent
illustration, wherein 80
percent or more of the plurality of particles have an inter-particle spacing
from 5 [tm to 15 [tm.
[0204] Illustration 43 is the method of any previous or subsequent
illustration, wherein the
plurality of particles comprise iron-containing particles, wherein a majority
of the iron-
containing particles have an diameter from 1 [tm to 40 [tm.
[0205] Illustration 44 is the method of any previous or subsequent
illustration, wherein iron-
containing particles comprise from 1% to 4% of a total volume of the aluminum
alloy.
[0206] Illustration 45 is the method of any previous or subsequent
illustration, wherein the
aluminum alloy further comprises manganese-containing dispersoids, wherein the
manganese-
containing dispersoids have a diameter from 10 nm and 1.5 [tm.
[0207] Illustration 46 is the method of any previous or subsequent
illustration, wherein the
manganese-containing dispersoids comprise up to 1% of a total volume of the
aluminum alloy.
[0208] Illustration 47 is a method for improving formability of a metal
product, the method
comprising: providing a cast metal product comprising a metal composite,
wherein the metal
composite comprises iron, magnesium, manganese, and silicon, wherein a ratio
of a silicon wt. %
in the metal composite to an iron wt. % in the metal composite is from 0.5 to
1.0, and wherein
the metal composite includes a plurality of particles including a-phase
intermetallic particles
comprising silicon and one or more of iron or manganese and 0-phase
intermetallic particles
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comprising one or more of iron or manganese; and homogenizing the cast metal
product to
control an inter-particle spacing of the plurality of particles and to control
a particle density of
the plurality of particles such to achieve a ratio of an inter-particle
spacing to particle density
from 0.00034tm to 0.0006/11.m.
[0209] Illustration 48 is the method of any previous or subsequent
illustration, wherein the
inter-particle spacing is from 1 p.m to 25 p.m.
[0210] Illustration 49 is the method of any previous or subsequent
illustration, wherein the
particle density is from 5 to 30,000 particles per i.tm2.
[0211] Illustration 50 is the method of any previous or subsequent
illustration, wherein the
particle density is from 5 to 1,000 particles per i.tm2.
[0212] Illustration 51 is the method of any previous or subsequent
illustration, wherein the
plurality of particles comprise a particle diameter from 1 p.m to 50 p.m.
[0213] Illustration 52 is the method of any previous or subsequent
illustration, wherein
homogenizing the cast metal product comprises heating the cast metal product
to a
homogenization temperature from 400 C to 800 C and soaking the cast metal
product at the
homogenization temperature for a time duration from 0.1 hours to 48 hours.
[0214] Illustration 53 is the method of any previous or subsequent
illustration, wherein the
homogenization temperature is within 25 C of a solidus temperature of the
cast metal product.
[0215] Illustration 54 is the method of any previous or subsequent
illustration, wherein
homogenizing the cast metal product further comprises subjecting the cast
metal product to one
or more of a hot rolling process or a cold rolling process.
[0216] Illustration 55 is a method of making an aluminum alloy product, the
method
comprising: preparing a cast aluminum alloy product, wherein the cast aluminum
alloy product
comprises a 3xxx series aluminum alloy including aluminum, iron, magnesium,
manganese, and
silicon, wherein a ratio of a silicon wt. % in the 3xxx series aluminum alloy
to an iron wt. % in
the 3xxx series aluminum alloy is from 0.5 to 1.0, and wherein the cast
aluminum alloy product
includes 0-phase intermetallic particles comprising aluminum and one or more
of iron or
manganese and a-phase intermetallic particles comprising aluminum, silicon,
and one or more of
iron or manganese; and homogenizing the cast aluminum alloy product to form a
homogenized
aluminum alloy product by: heating the cast aluminum alloy product to a
homogenization
temperature from 575 C to 615 C; and soaking the cast aluminum alloy product
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homogenization temperature for a time duration between 12 hours and 36 hours;
wherein silicon
from the 3xxx series aluminum alloy diffuses into and transforms at least a
fraction of the f3-
phase intermetallic particles into a-phase intermetallic particles.
[0217] Illustration 56 is the method of any previous or subsequent
illustration, wherein the
time duration is between 24 hours and 36 hours.
[0218] Illustration 57 is the method of any previous or subsequent
illustration, wherein the
time duration is between 24 hours and 30 hours.
[0219] Illustration 58 is the method of any previous or subsequent
illustration, wherein the
homogenization temperature is from 580 C to 610 C.
[0220] Illustration 59 is the method of any previous or subsequent
illustration, wherein the
homogenization temperature is within 25 C of a solidus temperature of the
3xxx series
aluminum alloy.
[0221] Illustration 60 is the method of any previous or subsequent
illustration, wherein,
during the soaking, iron diffuses out of the 0-phase intermetallic particles
and is replaced by
manganese.
[0222] Illustration 61 is the method of any previous or subsequent
illustration, wherein,
during the soaking, iron diffuses out of the 0-phase intermetallic particles
and combines with
dispersoids present within the cast aluminum alloy product to form a-phase
intermetallic
particles.
[0223] Illustration 62 is the method of any previous or subsequent
illustration, wherein the
dispersoids comprise manganese.
[0224] Illustration 63 is the method of any previous or subsequent
illustration, wherein,
during the soaking, an average size of the 0-phase intermetallic particles
decreases as compared
to an average size of the 0-phase intermetallic particles prior to soaking.
[0225] Illustration 64 is the method of any previous or subsequent
illustration, wherein,
during the soaking, a number density of the 0-phase intermetallic particles in
the cast aluminum
alloy product decreases as compared to a number density of the 0-phase
intermetallic particles in
the cast aluminum alloy product prior to soaking.
[0226] Illustration 65 is the method of any previous or subsequent
illustration, wherein,
during the soaking, 30% to 100% of the 0-phase intermetallic particles are
transformed into a-
phase intermetallic particles.
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[0227] Illustration 66 is the method of any previous or subsequent
illustration, wherein a
ratio of an a-phase intermetallic particle number density to a 0-phase
intermetallic particle
number density in the homogenized aluminum alloy product is from 2 to 1000.
[0228] Illustration 67 is the method of any previous or subsequent
illustration, wherein a
ratio of an a-phase intermetallic particle number density to a 0-phase
intermetallic particle
number density in the cast aluminum alloy product is from 0.3 to 3.
[0229] Illustration 68 is the method of any previous or subsequent
illustration, wherein the
ratio of the silicon wt. % to the iron wt. % in the 3xxx series aluminum alloy
is from 0.55 to 0.9.
[0230] Illustration 69 is the method of any previous or subsequent
illustration, wherein the
3xxx series aluminum alloy comprises: from 0.8-1.4 wt. % magnesium; from 0.8-
1.3 wt. %
manganese; up to 0.25 wt. % copper; from 0.25-0.7 wt. % silicon; up to 0.7 wt.
% iron; up to
0.25 wt. % zinc; and aluminum.
[0231] Illustration 70 is the method of any previous or subsequent
illustration, wherein
preparing the cast aluminum alloy product comprises preparing a molten 3xxx
series aluminum
alloy and casting the molten 3xxx series aluminum alloy.
[0232] Illustration 71 is the method of any previous or subsequent
illustration, wherein
preparing the molten 3xxx series aluminum alloy comprises melting a
combination of a 3xxx
series source aluminum alloy and a 5xxx series source aluminum alloy.
[0233] Illustration 72 is the method of any previous or subsequent
illustration, wherein the
3xxx series source aluminum alloy and the 5xxx series source aluminum alloy
are from a
recycled source.
[0234] Illustration 73 is the method of any previous or subsequent
illustration, wherein
preparing the molten 3xxx series aluminum alloy further comprises melting a
4xxx series
aluminum alloy or a 6xxx series aluminum alloy with the 3xxx series source
aluminum alloy and
the 5xxx series source aluminum alloy.
[0235] Illustration 74 is the method of any previous or subsequent
illustration, wherein the
homogenization temperature is a first homogenization temperature, and wherein
the method
further comprises: reducing a temperature of the homogenized aluminum alloy
product to a
second homogenization temperature less than the first homogenization
temperature; and soaking
the homogenized aluminum alloy product at the second homogenization
temperature for a
second time duration.
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[0236] Illustration 75 is the method of any previous or subsequent
illustration, wherein the
second time duration is from 1 hour to 24 hours.
[0237] Illustration 76 is the method of any previous or subsequent
illustration, wherein the
second homogenization temperature is from 500 C to 600 C.
[0238] Illustration 77 is the method of any previous or subsequent
illustration, wherein
soaking the homogenized aluminum alloy product at the second homogenization
temperature
controls a surface quality of the homogenized aluminum alloy product.
[0239] Illustration 78 is the method of any previous or subsequent
illustration, further
comprising subjecting the homogenized aluminum alloy product to one or more
rolling processes
to produce a rolled aluminum alloy product.
[0240] Illustration 79 is an aluminum alloy product, comprising: a
homogenized 3xxx series
aluminum alloy including aluminum, iron, magnesium, manganese, and silicon,
wherein a ratio
of a silicon wt. % in the homogenized 3xxx series aluminum alloy to an iron
wt. % in the
homogenized 3xxx series aluminum alloy is from 0.5 to 1.0, and wherein the
homogenized 3xxx
series aluminum alloy includes a-phase intermetallic particles comprising
aluminum, silicon, and
one or more of iron or manganese, wherein at least a portion of the a-phase
intermetallic
particles are transformed from 0-phase intermetallic particles comprising
aluminum and one or
more of iron or manganese during homogenization of the homogenized 3xxx series
aluminum
alloy.
[0241] Illustration 80 is the aluminum alloy product of any previous or
subsequent
illustration, wherein a ratio of an a-phase intermetallic particle number
density in the
homogenized 3xxx series aluminum alloy to a 0-phase intermetallic particle
number density in
the homogenized 3xxx series aluminum alloy is from 2 to 1000 or wherein a
ratio of a volume %
of the a-phase intermetallic particles to a volume % of the 0-phase
intermetallic particle is from
0.6 to 1000.
[0242] Illustration 81 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the homogenized 3xxx series aluminum alloy is subjected
to one or more
rolling processes.
[0243] Illustration 82 is the aluminum alloy product of any previous or
subsequent
illustration, wherein the homogenized 3xxx series aluminum alloy comprises:
from 0.8-1.4 wt. %
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magnesium; from 0.8-1.3 wt. % manganese; up to 0.25 wt. % copper; from 0.25-
0.7 wt. %
silicon; up to 0.7 wt. % iron; up to 0.25 wt. % zinc; and aluminum.
[0244] Illustration 83 is the aluminum alloy product of any previous
illustration, prepared by
the method of any previous illustration.
[0245] Illustration 84 is the method of any previous illustration,
comprising a method of
making the aluminum alloy product of any previous illustration.
[0246] All patents, publications and abstracts cited above are incorporated
herein by
reference in their entirety. The foregoing description of the embodiments,
including illustrated
embodiments, has been presented only for the purpose of illustration and
description and is not
intended to be exhaustive or limiting to the precise forms disclosed. Numerous
modifications,
adaptations, and uses thereof will be apparent to those skilled in the art.
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Representative Drawing