Note: Descriptions are shown in the official language in which they were submitted.
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SURFACE TREATMENT OF METAL SUBSTRATES SIMULTANEOUS WITH
SOLUTION HEAT TREATMENT OR CONTINUOUS ANNEALING
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Application
No. 63/248,171, filed on September 24, 2021, which is hereby incorporated by
reference in
its entirety.
FIELD
[0002] The present disclosure relates to metallurgy generally and more
specifically to
techniques for simultaneously performing a surface treatment operation and a
heat treatment
operation or continuous annealing operation on a metal substrate.
BACKGROUND
[0003] A variety of treatment processes can be useful for transforming
metal substrates
into processed metal products. The metal substrates may be subjected to one or
more forming
processes (e.g., roll-forming, stamping, etc.). For example, the metal
substrates can be
subjected to a continuous annealing process, a solution heat treatment
process, a surface
treatment process, a quenching process, or other suitable processes. The
processes can
improve certain characteristics of the metal substrates. The characteristics
can include bond
durability, hardness, corrosion resistance, or other suitable characteristics.
In conventional
processing techniques, the described processes are typically performed in
sequence (i.e., one
process at a time followed by a subsequent process, etc.). But, this
sequential performance of
processes may create shaped metal products with less than optimal
characteristics or other
performance indicators. Additionally, performing the processes in certain
sequences may
degrade a surface of the metal substrates. For example, performing a solution
heat treatment
subsequent to a surface treatment may destroy or otherwise degrade the effects
of the surface
treatment.
SUMMARY
[0004] 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
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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.
[0005] The present disclosure provides techniques, products, and methods
for
simultaneously performing a surface treatment operation along with a solution
heat treatment
operation or a continuous annealing operation to produce a processed metal
product. An
elongated metal substrate can be subjected to a solution heat treatment
operation or a
continuous annealing operation. Additionally, the elongated metal substrate
can be subjected
to a surface treatment operation. In some examples, the solution heat
treatment operation or
continuous annealing operation and the surface treatment operation can be
performed
simultaneously using super-heated steam while also heating the elongated metal
substrate, for
example. Optionally, a moisture content of the super-heated steam can be less
than or equal
to 10%. Optionally, the elongated metal substrate can be passed into a furnace
that can
include one or more nozzles for spraying super-heated steam onto the elongated
metal
substrate.
[0006] Optionally, the elongated metal substrate can include an aluminum
alloy sheet
(e.g., a sheet comprising a 2xxx alloy, a 5xxx alloy, a 6xxx alloy, a 7xxx
alloy, etc.).
Optionally, the elongated metal substrate can be subjected to a quenchant that
can include
water. The water can optionally include additives, such as Mn, Ce, Zr, Mo, a
silicate, a silane,
a sealant, or a combination thereof Treatment with the quenchant may
optionally create a
surface layer on the elongated metal substrate that can include the additives.
Optionally, the
super-heated steam can include an inhibiting material, such as Mn, Ce, Zr, Mo,
or a
combination thereof, which may optionally be incorporated into or on a surface
or surface
layer of the elongated metal substrate. Additionally, the surface layer can
include the
inhibiting material.
[0007] Optionally, the processed metal product can include a surface layer
produced by
the solution heat treatment process or continuous annealing process and the
surface treatment
process. For example, the surface layer may include at least one of boehmite,
bayerite,
diaspore, or corundum. The surface layer can have a thickness that can be from
10 nm to 500
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nm, such as from 10 nm to 20 nm, from 20 nm to 50 nm, from 50 nm to 100 nm,
from 100
nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250 nm, from 250 nm to 300
nm,
from 300 nm to 350 nm, from 350 nm to 400 nm, from 400 nm to 450 nm, or from
450 nm to
500 nm.
[0008] Optionally, the elongated metal substrate can include an aluminum
alloy sheet
metal tube. Optionally, the aluminum alloy sheet metal tube can be prepared by
roll-forming
an aluminum alloy sheet metal into a tubular shape and welding edges of the
tubular shape
together to enclose the aluminum alloy sheet metal tube, such as into a hollow
cross-sectional
shape. Optionally, the solution heat treatment process or continuous annealing
process and
the surface treatment process can be performed using a combination of flame
pyrolysis and
induction heating. Optionally, the solution heat treatment process or
continuous annealing
process and the surface treatment process can be performed subsequent to
welding the
elongated metal substrate to produce a metal tube. In some examples, a metal
tube may be
referred to as having a tubular shape or tubular cross-sectional shape. In
some examples, a
metal tube may be referred to as a metal pipe. In some examples, a metal tube
has a tubular or
hollow cross-sectional shape. For example, a metal tube may have a circular or
non-circular
cross-sectional shape defined by the metal and including an opening or hollow
region within
a perimeter defined by the metal. For example, a metal tube may have a
circular, non-
circular, oval, or polygonal (e.g., triagonal, quadrilateral, pentagonal,
hexagonal, heptagonal,
octagonal, etc.) cross-sectional shape, including regular or non-regular cross-
sectional shapes.
Metal tubes having non-circular cross-sectional shapes may have cross-
sectional shapes with
linear sections or curved sections, including concave and/or convex curved
sections. In some
examples, a metal tube may have a star-shaped cross-section or other cross-
sectional shape
including both concave and convex regions. In some examples, metal tubes
having
polygonal cross-sectional shapes can have imperfect shapes, such as where
corners of the
shape are rounded. In some examples, metal tubes may have a D-shaped cross-
sectional
shape, a flat-sided oval cross-sectional shape, a rectangular cross-sectional
shape, a square
cross-sectional shape, or a circular cross-sectional shape.
[0009] The present disclosure provides a metal product that can include an
aluminum
alloy sheet metal substrate and a surface layer on the aluminum alloy sheet
metal substrate.
The surface layer on the aluminum alloy sheet metal substrate can include at
least one of
boehmite, bayerite, diaspore, or corundum. The surface layer can have a
thickness that can be
from 10 nm to 500 nm, such as from 10 nm to 20 nm, from 20 nm to 50 nm, from
50 nm to
100 nm, from 100 nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250 nm,
from 250
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nm to 300 nm, from 300 nm to 350 nm, from 350 nm to 400 nm, from 400 nm to 450
nm, or
from 450 nm to 500 nm.
[0010] Optionally, the aluminum alloy sheet metal substrate can include a
solution heat
treatable aluminum alloy sheet metal substrate. For example, the aluminum
alloy sheet metal
substrate can include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a
6xxx
aluminum alloy, or a 7xxx aluminum alloy. Optionally, the surface layer can
include at least
one of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant. Optionally, the
surface layer can be
generated by subjecting the aluminum alloy sheet metal substrate to super-
heated steam that
can be characterized by a moisture content of less than or equal to 10%.
Optionally, the
super-heated steam can include an inhibiting material that can include at
least one of Mn, Ce,
Zr, or Mo. Optionally, the surface layer can be, at least in part, generated
by exposing the
aluminum alloy sheet metal substrate to an aqueous quenchant. Optionally, the
quenchant can
include water and at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a
sealant.
[0011] The present disclosure provides a roll-formed metal product, such as
a roll-formed
metal tubular, that can include a roll-formed aluminum alloy sheet metal and a
surface layer
on the aluminum alloy sheet metal. The surface layer on the roll-formed
aluminum alloy
sheet metal can include at least one of boehmite, bayerite, diaspore, or
corundum. The surface
layer can have a thickness that can be from 10 nm to 500 nm, such as from 10
nm to 20 nm,
from 20 nm to 50 nm, from 50 nm to 100 nm, from 100 nm to 150 nm, from 150 nm
to 200
nm, from 200 nm to 250 nm, from 250 nm to 300 nm, from 300 nm to 350 nm, from
350 nm
to 400 nm, from 400 nm to 450 nm, or from 450 nm to 500 nm.
[0012] Optionally, the roll-formed aluminum alloy sheet metal can include
one of a 2xxx
aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Optionally,
the surface
layer can include at least one of Mn, Ce, Zr, Mo, a silicate, a silane, or a
sealant. Optionally,
the roll-formed aluminum alloy sheet metal can be prepared by roll-forming an
aluminum
alloy sheet metal. Optionally, the roll-formed aluminum alloy sheet metal
product can be a
roll-formed aluminum alloy sheet metal tube, prepared by roll-forming an
aluminum alloy
sheet metal into a tubular shape and by welding edges of the tubular shape
together to enclose
the roll-formed aluminum alloy sheet metal tube. Optionally, the roll-formed
aluminum alloy
sheet metal tube can include a treated aluminum alloy sheet metal tube. The
treated
aluminum alloy sheet metal can be subjected to a simultaneous solution heat
treat or
continuous annealing and surface treatment process using a combination of
flame pyrolysis
and induction heating, for example subsequent to welding the edges of the
tubular shape
together.
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[0013] Other objects and advantages will be apparent from the following
detailed
description of non-limiting examples.
BRIEF DESCRIPTION OF THE FIGURES
[0014] 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.
[0015] FIG. 1 provides a schematic illustration of an exemplary processing
line for
forming sheet metal from an elongated metal substrate that includes a
simultaneous solution
heat treat or continuous annealing and surface treatment operation.
[0016] FIG. 2 provides a schematic illustration of an exemplary processing
line for roll-
forming a sheet metal tube from an elongated metal substrate that includes a
simultaneous
solution heat treat or continuous annealing process and surface treatment
operation.
[0017] FIG. 3 provides a schematic illustration of a sub-system of the
exemplary
processing line of FIG. 2 for making processed metal products using
simultaneous solution
heat treatment or continuous annealing and solution treatment operations.
[0018] FIG. 4 provides a sectional side-view of a furnace that can be used
to
simultaneously perform solution heat treatment or continuous annealing and
surface
treatment operations.
[0019] FIG. 5 provides a flowchart of a process to create a processed metal
product by
simultaneously performing solution heat treatment or continuous annealing and
surface
treatment operations using super-heated steam.
[0020] FIG. 6 provides a sectional side-view of a processed metal product
having a
surface layer that can be created by simultaneously performing solution heat
treatment or
continuous annealing and surface treatment operations with respect to the
processed metal
product.
DETAILED DESCRIPTION
[0021] Described herein are systems and methods for simultaneously
performing a
surface treatment operation along with a solution heat treatment operation or
a continuous
annealing operation on a metal product, such as by using super-heated steam
while heating
the metal product. The simultaneous solution heat treatment operation or
continuous
annealing and surface treatment operation can be performed on one or more
elongated metal
substrates (e.g., an aluminum alloy substrate). The super-heated steam can be
applied to the
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elongated metal substrate while undergoing heating in a furnace (e.g., where
steam nozzles
are included in the furnace), using various operations (e.g., flame pyrolysis,
etc.), or using
other suitable techniques. Subsequent to the simultaneous solution heat
treatment operation or
continuous annealing operation and surface treatment operation, the elongated
metal substrate
can be formed into various processed metal products. For example, the
processed metal
products can include sheet metal (e.g., an aluminum alloy sheet metal
product), roll-formed
metal products, including tubes (e.g., a roll-formed and welded aluminum alloy
tube), or
other suitable processed metal products.
[0022] Optionally, a quenching operation can be performed in conjunction
with the
simultaneous solution heat treatment operation or continuous annealing
operation and surface
treatment operation. For example, the quenching operation can be performed
subsequent to
the simultaneous solution heat treatment operation or continuous annealing
operation and
surface treatment operation. The quenching operation, individually or in
combination with
the simultaneous solution heat treatment operation or continuous annealing
operation and
surface treatment operation, can create a surface layer on the elongated metal
substrate. In
some examples, alternative to or in addition to the quenching operation, the
simultaneous
solution heat treatment operation or continuous annealing operation and
surface treatment
operation can create the surface layer on the elongated metal substrate. The
surface layer can
include various elements and materials for various purposes. For example, the
surface layer
can include inhibitors for preventing or mitigating corrosion, or can
correspond to or include
stable phases of the base-metal alloy (e.g., stable aluminum phases) or stable
oxide or
hydrolyzed oxide phases, or can include other suitable elements and materials
for improving
characteristics or performance associated with the elongated metal substrate.
Definitions and Descriptions
[0023] 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.
[0024] In this description, reference is made to alloys identified by AA
numbers and
other related designations, such as "series" or "7xxx." For an understanding
of the number
designation system most commonly used in naming and identifying aluminum and
its alloys,
see "International Alloy Designations and Chemical Composition Limits for
Wrought
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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.
[0025] As used herein, a plate generally has a thickness of greater than
about 15 mm. For
example, a plate may refer to an aluminum product having a thickness of
greater than about
15 mm, greater than about 20 mm, greater than about 25 mm, greater than about
30 mm,
greater than about 35 mm, greater than about 40 mm, greater than about 45 mm,
greater than
about 50 mm, or greater than about 100 mm.
[0026] As used herein, a shate (also referred to as a sheet plate)
generally has a thickness
of from about 4 mm to about 15 mm. For example, a shate may have a thickness
of about 4
mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm,
about
11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
[0027] As used herein, a sheet generally refers to an aluminum product
having a
thickness of less than about 4 mm. For example, a sheet may have a thickness
of less than
about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm,
less than
about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).
[0028] Reference may be made in this application to alloy temper or
condition. For an
understanding of the alloy temper descriptions most commonly used, see
"American National
Standards (ANSI) H35 on Alloy and Temper Designation Systems." An F condition
or
temper refers to an aluminum alloy as fabricated. An 0 condition or temper
refers to an
aluminum alloy after annealing. An Hxx condition or temper, also referred to
herein as an H
temper, refers to a non-heat treatable aluminum alloy after cold rolling with
or without
thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3
HX4, HX5,
HX6, HX7, HX8, or HX9 tempers. A Ti condition or temper refers to an aluminum
alloy
cooled from hot working and naturally aged (e.g., at room temperature). A T2
condition or
temper refers to an aluminum alloy cooled from hot working, cold worked and
naturally
aged. A T3 condition or temper refers to an aluminum alloy solution heat
treated, cold
worked, and naturally aged. A T4 condition or temper refers to an aluminum
alloy solution
heat treated and naturally aged. A T5 condition or temper refers to an
aluminum alloy cooled
from hot working and artificially aged (at elevated temperatures). A T6
condition or temper
refers to an aluminum alloy solution heat treated and artificially aged. A T7
condition or
temper refers to an aluminum alloy solution heat treated and artificially
overaged. A T8x
condition or temper refers to an aluminum alloy solution heat treated, cold
worked, and
artificially aged. A T9 condition or temper refers to an aluminum alloy
solution heat treated,
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artificially aged, and cold worked. A W condition or temper refers to an
aluminum alloy
after solution heat treatment.
[0029] As used herein, terms such as "cast metal product," "cast product,"
"cast
aluminum alloy product," and the like are interchangeable and refer to a
product produced by
direct chill casting (including direct chill co-casting) or semi-continuous
casting, continuous
casting (including, for example, by use of a twin belt caster, a twin roll
caster, a block caster,
or any other continuous caster), electromagnetic casting, hot top casting, or
any other casting
method.
[0030] As used herein, the meaning of "room temperature" can include a
temperature of
from about 15 C to about 30 C, for example about 15 C, about 16 C, about 17
C, about
18 C, about 19 C, about 20 C, about 21 C, about 22 C, about 23 C, about 24
C, about
25 C, about 26 C, about 27 C, about 28 C, about 29 C, or about 30 C. As
used herein,
the meaning of "ambient conditions" can include temperatures of about room
temperature,
relative humidity of from about 20% to about 100 %, and barometric pressure of
from about
975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be
about 20 %,
about 21 %, about 22 %, about 23 %, about 24 %, about 25 %, about 26 %, about
27 %, about
28 %, about 29 %, about 30 %, about 31 %, about 32 %, about 33 %, about 34 %,
about 35
%, about 36 %, about 37 %, about 38 %, about 39 %, about 40 %, about 41 %,
about 42 %,
about 43 %, about 44 %, about 45 %, about 46 %, about 47 %, about 48 %, about
49 %, about
50%, about 51 %, about 52 %, about 53%, about 54 %, about 55 %, about 56%,
about 57
%, about 58 %, about 59 %, about 60 %, about 61 %, about 62 %, about 63 %,
about 64 %,
about 65 %, about 66 %, about 67 %, about 68 %, about 69 %, about 70 %, about
71 %, about
72 %, about 73 %, about 74 %, about 75 %, about 76 %, about 77 %, about 78 %,
about 79
%, about 80 %, about 81 %, about 82%, about 83 %, about 84 %, about 85 %,
about 86 %,
about 87 %, about 88 %, about 89 %, about 90 %, about 91 %, about 92 %, about
93 %, about
94 %, about 95 %, about 96 %, about 97%, about 98 %, about 99 %, about 100%,
or
anywhere in between. For example, barometric pressure can be about 975 mbar,
about 980
mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about
1005 mbar,
about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030
mbar,
about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or
anywhere in
between.
[0031] All ranges disclosed herein are to be understood to encompass any
and all
subranges subsumed therein. For example, a stated range of "1 to 10" should be
considered
to include any and all subranges between (and inclusive of) the minimum value
of 1 and the
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maximum value of 10; that is, all subranges beginning with a minimum value of
1 or more,
e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.
Unless stated
otherwise, the expression "up to" when referring to the compositional amount
of an element
means that element is optional and includes a zero percent composition of that
particular
element. Unless stated otherwise, all compositional percentages are in weight
percent (wt.
%).
[0032] As used herein, the meaning of "a," "an," and "the" includes
singular and plural
references unless the context clearly dictates otherwise.
[0033] In the following examples, aluminum alloy products and their
components may be
described in terms of their elemental composition in weight percent (wt. %).
In each alloy,
the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of all
impurities.
[0034] Incidental elements, such as grain refiners and deoxidizers, or
other additives may
be present in the invention and may add other characteristics on their own
without departing
from or significantly altering the alloy described herein or the
characteristics of the alloy
described herein.
[0035] Unavoidable impurities, including materials or elements may be
present in an
alloy in minor amounts due to inherent properties of aluminum or leaching from
contact with
processing equipment. Some alloys, as described, may contain no more than
about 0.25 wt.
% of any element besides the alloying elements, incidental elements, and
unavoidable
impurities.
Methods of Producing the Alloys and Aluminum Alloy Products
[0036] The alloys described herein can be cast using any suitable casting
method known
to those of ordinary skill in the art. As a few non-limiting examples, the
casting process can
include a direct chill (DC) casting process or a continuous casting (CC)
process. The
continuous casting system can include a pair of moving opposed casting
surfaces (e.g.,
moving opposed belts, rolls or blocks), a casting cavity between the pair of
moving opposed
casting surfaces, and a molten metal injector. The molten metal injector can
have an end
opening from which molten metal can exit the molten metal injector and be
injected into the
casting cavity.
[0037] A clad layer can be attached to a core layer to form a cladded
product by any
means known to persons of ordinary skill in the art. For example, a clad layer
can be
attached to a core layer by direct chill co-casting (i.e., fusion casting) as
described in, for
example, U.S. Patent Nos. 7,748,434 and 8,927,113, both of which are hereby
incorporated
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by reference in their entireties; by hot and cold rolling a composite cast
ingot as described in
U.S. Patent No. 7,472,740, which is hereby incorporated by reference in its
entirety; or by
roll bonding to achieve metallurgical bonding between the core and the
cladding. The initial
dimensions and final dimensions of the clad aluminum alloy products described
herein can be
determined by the desired properties of the overall final product.
[0038] A roll bonding process can be carried out in different manners. For
example, the
roll-bonding process can include both hot rolling and cold rolling. Further,
the roll bonding
process can be a one-step process or a multi-step process in which the
material is gauged
down during successive rolling steps. Separate rolling steps can optionally be
separated by
other processing steps, including, for example, annealing steps, cleaning
steps, heating steps,
cooling steps, and the like.
[0039] A cast ingot, cast slab, or other cast product can be processed by
any suitable
means. Such processing steps include, but are not limited to, homogenization,
hot rolling,
cold rolling, continuous annealing, solution heat treatment, and an optional
pre-aging step.
[0040] In a homogenization step, a cast product is heated to a temperature
ranging from
about 400 C to about 560 C. For example, the cast product can be heated to a
temperature
of about 400 C, about 410 C, about 420 C, about 430 C, about 440 C, about
450 C,
about 460 C, about 470 C, about 480 C, about 490 C, about 500 C, about
510 C, about
520 C, about 530 C, about 540 C, about 550 C, or about 560 C. In some
examples,
homogenization is performed at a temperature within 50 C of a solidus
temperature of the
cast product or alloy thereof The product is then allowed to soak (i.e., held
at the indicated
temperature) for a period of time to form a homogenized product. In some
examples, the
total time for the homogenization step, including the heating and soaking
phases, can be up to
24 hours. For example, the product can be heated up to 500 C and soaked, for
a total time of
up to 18 hours for the homogenization step. Optionally, the product can be
heated to below
490 C and soaked, for a total time of greater than 18 hours for the
homogenization step. In
some cases, the homogenization step comprises multiple processes. In some non-
limiting
examples, the homogenization step includes heating a cast product 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, a cast product can be heated to about 465 C for about 3.5 hours
and then
heated to about 480 C for about 6 hours.
[0041] Following a homogenization step, a hot rolling step can be
performed. Prior to the
start of hot rolling, the homogenized product can be allowed to cool to a
temperature between
300 C to 450 C. For example, the homogenized product can be allowed to cool
to a
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temperature of between 325 C to 425 C or from 350 C to 400 C. The
homogenized
product can then be hot rolled at a temperature between 300 C to 450 C to
form a hot rolled
plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm
and 200 mm (e.g.,
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, 120mm, 130mm, 140mm, 150mm, 160mm, 170 mm, 180
mm, 190 mm, 200 mm, or anywhere in between).
[0042] Optionally, the cast product can be a continuously cast product that
can be
allowed to cool to a temperature between 300 C to 450 C. For example, the
continuously
cast product can be allowed to cool to a temperature of between 325 C to 425
C or from
350 C to 400 C. The continuously cast products can then be hot rolled at a
temperature
between 300 C to 450 C to form a hot rolled plate, a hot rolled shate or a
hot rolled sheet
having a gauge between 3 mm and 200 mm (e.g., 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). During hot rolling, temperatures and other operating parameters can
be controlled
so that the temperature of the hot rolled intermediate product upon exit from
the hot rolling
mill is no more than 470 C, no more than 450 C, no more than 440 C, or no
more than 430
C.
[0043] Cast, homogenized, or hot-rolled products can be cold rolled using
cold rolling
mills into thinner products, such as a cold rolled sheet. The cold rolled
product can have a
gauge between about 0.5 to 10 mm, e.g., between about 0.7 to 6.5 mm.
Optionally, the cold
rolled product can have a gauge of 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 mm. The cold rolling can be performed to result in a
final gauge
thickness that represents a gauge reduction of up to 85 % (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%, or up to 85 %
reduction)
as compared to a gauge prior to the start of cold rolling. Optionally, an
interannealing step
can be performed during the cold rolling step, such as where a first cold
rolling process is
applied, followed by an annealing process (interannealing), followed by a
second cold rolling
process. The interannealing step can be performed at a temperature of from
about 300 C to
about 450 C (e.g., about 310 C, about 320 C, about 330 C, about 340 C,
about 350 C,
about 360 C, about 370 C, about 380 C, about 390 C, about 400 C, about
410 C, about
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420 C, about 430 C, about 440 C, or about 450 C). In some cases, the
interannealing step
comprises multiple processes. In some non-limiting examples, the
interannealing step
includes heating the partially cold rolled product 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 partially cold rolled product can be heated to about 410 C for about 1
hour and then
heated to about 330 C for about 2 hours.
[0044] Subsequently, a cast, homogenized, or rolled product can undergo a
solution heat
treatment step. The solution heat treatment step can be any suitable treatment
for the sheet
which results in solutionizing of the soluble particles. The cast,
homogenized, or rolled
product can be heated to a peak metal temperature (PMT) of up to 590 C (e.g.,
from 400 C
to 590 C) and soaked for a period of time at the PMT to form a hot product.
For example,
the cast, homogenized, or rolled product can be soaked at 480 C for a soak
time of up to 30
minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10
minutes, 20
minutes, 25 minutes, or 30 minutes). After heating and soaking, the hot
product is rapidly
cooled at rates greater than 200 C/s to a temperature between 500 and 200 C
to form a heat-
treated product. In one example, the hot product is cooled at a quench rate of
above 200
C/second at temperatures between 450 C and 200 C. Optionally, the cooling
rates can be
faster in other cases.
[0045] After quenching, the heat-treated product can optionally undergo a
pre-aging
treatment by reheating before coiling. The pre-aging treatment can be
performed at a
temperature of from about 70 C to about 125 C for a period of time of up to
6 hours. For
example, the pre-aging treatment can be performed at a temperature of about 70
C, about 75
C, about 80 C, about 85 C, about 90 C, about 95 C, about 100 C, about 105
C, about
110 C, about 115 C, about 120 C, or about 125 C. Optionally, the pre-aging
treatment
can be performed for about 30 minutes, about 1 hour, about 2 hours, about 3
hours, about 4
hours, about 5 hours, or about 6 hours. The pre-aging treatment can be carried
out by passing
the heat-treated product through a heating device, such as a device that emits
radiant heat,
convective heat, induction heat, infrared heat, or the like.
[0046] The cast products described herein can be used to make products in
the form of
sheets, 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 a hot rolling step. In the hot
rolling step, the cast
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, the cast product can be hot rolled to a plate having a
final gauge
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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. In some cases, plates may be rolled into thinner metal
products, such as
sheets.
Methods and Systems for Making Metal Products
[0047] Metal substrates, such as metal sheets, shates, and plates, may be
used for a
variety of applications. In some cases, metal substrates may be used to make
formed metal
products through one or more forming processes, such as stamping or roll-
forming. Roll-
forming refers to a process in which a metal substrate, such as an elongated
metal substrate, is
subjected to a bending operation where two or more rollers force the elongated
metal
substrate to undergo plastic deformation along a longitudinal or rolling axis
of the substrate
as it moves between the rollers. Elongated metal substrates may be in the form
of a coil of
sheet metal, for example, which can be used for a variety of applications,
including preparing
sheet metal blanks, which can be stamped, shaped, or otherwise processed.
Elongated metal
substrates, like sheet metal coils, are typically used for roll-forming
operations, as roll-
forming can be a continuous or semi-continuous process in which long lengths
of metal
substrates are processed to bend the metal substrate the same way along a
longitudinal (i.e.,
the longest) axis of the substrate. As used herein, an elongated metal
substrate refers to a
metal substrate having a length that is greater than a width. In some cases, a
length of an
elongated metal substrate may be 1.5-1000 times (or more) the width of the
substrate. For
example, a metal coil may be hundreds of meters long, but only a few or a
fraction of a meter
wide. In some examples, a metal coil can be bent at one or more points along
its width but
entirely along its length by roll-forming. In some cases, an elongated metal
substrate may be
referred to as a metal strip. Roll-formed metal products may be sectioned into
shorter
segments. Elongated metal substrates may be sectioned into smaller portions,
where a length
and width may be comparable (e.g., ratio of length to width may be from about
0.5 to about
1.5), which may be referred to herein as a metal blank. Metal substrates, such
as metal
blanks, subjected to forming by stamping may be referred to herein as stamped
products or
stamped metal products. Metal substrates subjected to roll-forming may be
referred to herein
as roll-formed products or roll-formed metal products.
[0048] The elongated metal substrate may be subjected to one or more
processes prior to
or after forming, or generally as part of the manufacturing process for the
elongated metal
substrate. For example, the elongated metal substrate can be subjected to a
continuous
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annealing process, solution heat treatment process, a surface treatment
process, a quenching
process, or any combination thereof. In some examples, the elongated metal
substrate can be
subjected to the listed processes in a defined order (e.g., the solution heat
treat process or
continuous annealing process, then the surface treatment process, then the
quenching process,
etc.). However, individually performing the processes can reduce an efficiency
of producing
the roll-formed metal products. For example, an amount of time, energy, or
other resources
used for creating the roll-formed metal product may be excessively high.
Additionally, by
performing the processes individually, additional processing may need to be
performed to
form a processed metal product such as sheet metal or a roll-formed metal
object, such as a
tube. For example, performing a solution heat treatment operation or
continuous annealing
operation subsequent to a surface treatment operation may destroy or otherwise
degrade the
effectiveness of the surface treatment operation, and this may necessitate an
additional
surface treatment operation.
[0049] The techniques described herein, however, allow for more than one
process to be
performed simultaneously during preparation of the processed metal product.
For example,
the solution heat treatment operation or continuous annealing operation and
the surface
treatment operation can be performed simultaneously. By performing the
solution heat
treatment operation or continuous annealing operation and the surface
treatment operation
simultaneously, the efficiency of creating the resulting processed metal
product may increase
and the processed metal product may include improved characteristics (e.g.,
bond durability,
hardness, strength, surface characteristics, etc.).
[0050] FIG. 1 provides a schematic illustration of an exemplary processing
line 100 for
forming processed metal products from an elongated metal substrate. In some
examples, the
processing line 100 can be configured to produce processed metal products that
can include
sheet metal (e.g., aluminum alloy or other suitable alloy sheet metal). The
processing line 100
can include a furnace, a step, a station, or other suitable component that can
simultaneously
perform solution heat treatment or continuous annealing and surface treatment
operations
with respect to the elongated metal substrate.
[0051] As illustrated, the processing line 100 includes two starting coils
(e.g., starting coil
102), various rollers 104, an elongated metal substrate 105, a furnace 106, a
quenching
station 108, a tension leveler 110, a pre-ageing station 112, and an ending
coil 114. The
elongated metal substrate 105 can extend from the starting coil 102 to the
ending coil 114
(e.g., passing through each component of the processing line 100 for preparing
the processed
metal product). The rollers 104 can aid in transporting the elongated metal
substrate 105.
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[0052] The furnace 106 can perform a solution heat treatment operation or
continuous
annealing operation and a surface treatment operation. In some examples, the
furnace 106 can
simultaneously perform the solution heat treatment operation or continuous
annealing
operation and the surface treatment operation. The solution heat treatment
operation or
continuous annealing operation can involve heating the elongated metal
substrate 105 to a
suitable temperature for dissolving alloying elements into the elongated metal
substrate 105,
for improving characteristics or performance with respect to the elongated
metal substrate
105, for modifying a temper of the elongated metal substrate, or the like. The
surface
treatment operation can involve one or more operations for altering a natural
surface of the
elongated metal substrate 105, such as to produce a surface layer, to improve
an adhesion
characteristic, or the like of the elongated metal substrate 105. In some
examples, the furnace
106 can use super-heated steam to perform a simultaneous heat treatment or
continuous
annealing and surface treatment operation. The super-heated steam can be
applied to the
elongated metal substrate 105 via nozzles or other suitable sources for the
super-heated
steam. Optionally, the super-heated steam can be defined by a low moisture
content (e.g., less
than 10%). In some examples, the super-heated steam can include additives
(e.g., inhibitors,
acids, etc.) for performing the surface treatment operation or for otherwise
improving
characteristics or performance of the elongated metal substrate 105. In some
examples, in
response to the simultaneous solution heat treatment or continuous annealing
and surface
treatment operation, no further surface treatment operation may be required to
produce the
processed metal product with the processing line 100.
[0053] The quenching station 108 can apply water or other suitable
quenching solutions
for quenching the elongated metal substrate 105. In some examples, the
elongated metal
substrate 105 can be subjected to a quenching process at the quenching station
108
subsequent to the simultaneous solution heat treatment or continuous annealing
and surface
treatment operation at the furnace 106. The quenching process can involve
subjecting the
elongated metal substrate 105 to the water or quenching solution for cooling
the elongated
metal substrate 105 without losing improved characteristics or performance
traits provided by
the simultaneous solution heat treatment or continuous annealing and surface
treatment
operation. In some examples, the quenching solution can include additives,
such as inhibitors,
acids, etc., for improving characteristics or performance traits of the
elongated metal
substrate 105.
[0054] FIG. 2 provides a schematic illustration of an exemplary processing
line 200 for
roll-forming a metal product from an elongated metal substrate 205. In some
examples, the
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processing line 200 can be configured to produce a processed metal product
such as metal
tubes (e.g., aluminum alloy or other suitable alloy roll-formed metal tube),
where ends of a
roll-formed metal substrate are welded to produce a closed shape, or other
roll-formed metal
products. Similar to the processing line 100, the processing line 200 can
include a furnace, a
step, or a station that can simultaneously perform solution heat treatment or
continuous
annealing and surface treatment operations with respect to the elongated metal
substrate 205.
[0055] As illustrated, the processing line 200 includes starting coil 201,
roll forming
station 206, a welding station 208, a scarfing station 210, a post-weld heat
treatment station
212, and a quench bath 214. The starting coil 201 can be similar or identical
to the starting
coil 102 of the processing line 100. The roll forming station 206 can include
one or more roll-
forming stands that can be used to form the elongated metal substrate 205,
such as into a
tubular-shaped elongated metal substrate 207. The welding station 208 can
perform one or
more optional welding operations relating to the elongated metal substrate
205. For example,
subsequent to forming the tubular shape at the roll-forming station 206, the
processing line
200 can use the welding station 208 to weld the elongated metal substrate 205
to produce a
tubular shape (e.g., an open tube, a closed tube, or other suitable shape).
Optionally, a forging
process can be performed (e.g., using one or more roll-forging stands)
subsequent to the
welding station 208. The scarfing station 210 can be used to scarf a surface
of the tubular-
shaped elongated metal substrate 207. Scarfing can involve removing defects
(e.g., burrs,
nicks, etc.) from one or more surfaces of the elongated metal substrate 205.
[0056] The heat treatment station 212 can optionally be used to perform
simultaneous
heat treatment and surface treatment operations. For example, the heat
treatment station 212
can use super-heated steam to perform the simultaneous heat treatment and
surface treatment
operation. In some examples, the heat treatment station 212 can optionally be
a post-weld
heat treatment station. While illustrated subsequent to the welding station
208, the heat
treatment station 212 can be performed at any suitable point with respect to
the processing
line 200. In some examples, the heat treatment station 212 can use flame
pyrolysis, induction
heating, exposure to super-heated steam, or other suitable operations, or a
combination
thereof to perform the simultaneous heat treatment and surface treatment
operation. In some
examples, flame pyrolysis can involve burning fuel (e.g., using gas burners)
to heat the
elongated metal substrate 205. Flame pyrolysis can be used in combination with
steam
nozzles that can spray super-heated steam on the elongated metal substrate 205
to create
stable phases of the substrate base-alloy (e.g., an aluminum alloy). In some
examples, the
combination of the flame pyrolysis and the steam nozzles can include
inhibitors, acids, or
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other suitable additives for use in applying the additives to the surface of
the elongated metal
substrate 205 via the steam nozzles or flame pyrolysis.
[0057] The quench bath 214 can include a quenching solution. In some
examples, the
quenching solution of the quench bath 214 can be similar or identical to the
quenching
solution of the quenching station 108 of the processing line 100. For example,
the quenching
solution optionally can include additives, such as inhibitors, acids, etc.,
for improving
characteristics or performance traits of the elongated metal substrate 205.
The tubular-shaped,
elongated metal substrate 205 can be subjected to a quenching process with
respect to the
quench bath 214 subsequent to the simultaneous solution heat treatment or
continuous
annealing and surface treatment operation at the heat treat station 212. The
quenching process
can involve subjecting the elongated metal substrate 205 to the quenching
solution for
cooling the elongated metal substrate 205 without losing improved
characteristics or
performance traits provided by the simultaneous solution heat treatment or
continuous
annealing and surface treatment operation. In some examples, the quench bath
214 can
involve reactive quenching with a quenching solution including one or more
salts,
decomposable surface treatment precursors (e.g., polymer precursors, etc.),
other suitable
reactive quenching material, or a combination thereof.
[0058] In some examples, the quenching solution (e.g., of the quenching
station 108
and/or the quench bath 214) can include additives. The additives can include
inorganic or
organic surface enhancing components that can include Zr, Mn, Ce, Mo,
silicates,
phosphates, silanes, or other suitable surface enhancing components. The
quenching solution
with the additives can be used to cool the elongated metal substrate 205 and
to seal a surface
layer that can be produced by the simultaneous solution heat treatment or
continuous
annealing and surface treatment operation. In some examples, the quenching
solution can be
used to include the additives into the surface layer for increasing
performance characteristics
(e.g., hardness, corrosion-resistance, bond durability, etc.) of the elongated
metal substrate
205.
[0059] While described above as sheet metal, a roll-formed sheet metal
product, a roll-
formed sheet metal tube, or a combination thereof, the elongated metal
substrate 105 or 205
can include various materials regardless of configuration. For example, the
sheet metal
configuration of the elongated metal substrate 105 can include one of a 2xxx
aluminum alloy,
a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.
Additionally, the
roll-formed sheet metal tube configuration of the elongated metal tube 207 can
include one of
a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx
aluminum
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alloy. The elongated metal substrate 105 can include additional other suitable
alloys.
Additionally, the processed metal product produced from the processing lines
100 and 200
can exhibit similar performance characteristics. For example, the processing
line 100 or 200
can produce a processed metal product that exhibits an improvement to a bond
durability
characteristic as compared to processed metal products that are produced in
substantially the
same way but without performing surface treatment, such as where the elongated
metal
substrate is not subjected to superheated steam during a solution heat
treatment or continuous
annealing operation. In some examples, bond durability may be determined
according to an
ASTM D3762 standard test or a FLTM BV 101-07 standard test. In some examples,
the
processed metal product can exhibit a bond durability of from 30 cycles to 65
cycles or more.
[0060] FIG. 3 provides a schematic illustration of a sub-system 300 of the
processing line
200 for producing processed metal products using simultaneous solution heat
treatment or
continuous annealing and solution treatment operations. The elongated metal
substrate 205 is
illustrated as moving along direction 310 through the sub-system 300. The sub-
system 300
can include a roll-forming stand 305, an optional welding station 315, a set
of magnetic field
sources 320, a set of flame pyrolysis sources 335, and a set of steam nozzles
350. A bent
metal product 330 can exit the sub-system 300 after passing through sub-system
300.
Although the elongated metal substrate 205 is shown as originating from a
coil, other
configurations may include processing the elongated metal substrate 205 as a
metal blank or a
metal strip. Additionally, although the elongated metal substrate 205 is shown
as a flat sheet,
other configurations are possible (e.g., a tubular-shaped, elongated metal
substrate 207, etc.).
[0061] The roll-forming stand 305 may include two or more rollers driven
along
independent rotation axes in a configuration to receive and pass the elongated
metal substrate
205 between the rollers. The rollers may include roller surfaces with surface
profiles
relatively oriented with respect to each other for bending, in a direction
different from the
direction 310, the elongated metal substrate 205 as it passes between the
rollers along the
direction 310. Optionally, the roll-forming stand 305 can include a top roller
having a top
rotation axis and a top roller surface and a bottom roller having a bottom
rotation axis and a
bottom roller surface. Optionally, other roller configurations may be included
in the roll-
forming stand 305, such as a forming roller oriented with respect to a top
roller or a bottom
roller with a rotation axis and surface profile positioned relative to other
rollers to bend the
elongated metal substrate 205 as it passes through the roll-forming stand 305.
The welding
station 315 may be optional and may allow the elongated metal substrate 205 to
be formed
into various shapes. For example, the welding station 315 may allow the
elongated metal
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substrate 205 to become the tubular-shaped elongated metal substrate 207 or
any other
suitable shape for the elongated metal substrate 205.
[0062] Each magnetic field source 320 may generate a time-varying magnetic
field to
heat a portion of the elongated metal substrate 205 via induction heating.
Each flame
pyrolysis source 335 may expose a portion of the elongated metal substrate 205
to heat (or
other suitable outputs from a flame pyrolysis system). Each steam nozzle 350
may expose a
portion of the elongated metal substrate 205 to super-heated steam and,
optionally, various
additives. Depending on the configuration, different portions of elongated
metal substrate 205
may be heated by the different magnetic field sources 320, flame pyrolysis
sources 335,
and/or steam nozzles. The magnetic field sources 320, the flame pyrolysis
sources 335,
and/or the steam nozzles 350 may be positioned before and/or after the roll-
forming stand
305. As illustrated, the magnetic field sources 320, the flame pyrolysis
sources 335, and the
steam nozzles 350 are positioned afterthe roll-forming stand 305 but they need
not be in
other embodiments and may be positioned in any suitable location with respect
to the sub-
system 300. The magnetic field sources 320, the flame pyrolysis sources 335,
and/or the
steam nozzles 350 may be independently positioned on atop side or bottom side
of the
elongated metal substrate 205. A position of the magnetic field sources 320,
the flame
pyrolysis sources 335, and/or the steam nozzles 350 may, at least in part, be
governed by the
particular bend operation achieved by the roll-forming stand 305. For example,
an interior
bend surface of elongated metal substrate 205 may face a magnetic field source
320, a flame
pyrolysis source 335, a steam nozzle 350, or a combination thereof positioned
after the roll-
forming stand 305. Although a combination of magnetic field sources 320, flame
pyrolysis
sources 335, and steam nozzles 350 are shown in the sub-system 300, the
magnetic field
sources 320, the flame pyrolysis sources 335, and the steam nozzles 350 may be
used alone
or in any combination in any desirable number. For example, the sub-system 300
may include
one or more magnetic field sources 320, one or more steam nozzles 350 and no
flame
pyrolysis sources 335. As another example, the sub-system 300 may include one
or more
flame pyrolysis sources 335, one or more steam nozzles 350, and no magnetic
field sources
320.
[0063] In some examples, the steam nozzles 350 may apply super-heated steam
that
includes additives, such as inhibitors, to the elongated metal substrate 205.
The additives can
include inhibitors such as Mn, Ce, Zr, Mo, other suitable inhibiting elements
or compounds,
or a combination thereof Additionally or alternatively, the additives can
include acids,
HNO3, or other suitable acids or inhibiting compounds. The additives can alter
a natural
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surface of the elongated metal substrate 205, such as to produce a surface
layer, to improve
an adhesion characteristic, or the like of the elongated metal substrate 205.
[0064] The heating may involve performing the solution heat treating or
continuous
annealing and surface treatment operations. In this example, the heating may
modify a natural
surface of the elongated metal substrate 205, such as to produce a surface
layer, to improve
an adhesion characteristic, or the like of the elongated metal substrate 205.
The heating may
increase a temperature of a portion of elongated metal substrate 205 to or
above a
temperature sufficient to, temporarily or permanently, increase formability or
plasticity of the
portion of the elongated metal substrate 205. In some cases, the heating may
be of a
sufficient time duration to modify a temper of the portion of the elongated
metal substrate
205. Optionally, the heating may overage the portion of the elongated metal
substrate 205.
The heating may raise the temperature of the portion of the elongated metal
substrate 205 to,
for example, between 50 C and 400 C, such as between 100 C and 300 C.
[0065] FIG. 4 provides a sectional side-view of components 400 of a furnace
(e.g., the
furnace 106 of the processing line 100) that can be used to simultaneously
perform solution
heat treatment or continuous annealing and surface treatment operations.
Various components
400 of the furnace are illustrated and can include a set of steam nozzles 402,
a set of nozzle
boxes 404 (e.g., containing natural gas burner nozzles), and other suitable
components of the
furnace. As illustrated, each steam nozzle 402 can be positioned opposite a
nozzle box 404.
Additionally as illustrated, the steam nozzles 402 and the nozzle boxes 404
are alternating in
the furnace, though this need not be the case and other configurations are
contemplated. The
elongated metal substrate can be positioned in a middle portion of the furnace
such that the
steam nozzles 402 and the nozzle boxes 404 can apply, to the elongated metal
substrate 105,
super-heated steam, heat, or other suitable outputs from the steam nozzles 402
or the nozzle
boxes 404. The elongated metal substrate can be passed through the furnace and
can receive
tension force such that, while the elongated metal substrate is in the
furnace, the elongated
metal substrate may be taut or otherwise flat for receiving the super-heated
steam.
[0066] In some examples, the steam nozzles 402 can spray or otherwise
suitably apply
the super-heated steam to one or more portions of the elongated metal
substrate. The super-
heated steam can be dry or may include a limited amount of moisture content
(e.g., less than
10%). The super-heated steam can be used to perform the simultaneous heat
treatment and
surface treatment operation. The simultaneous heat treatment and surface
treatment operation
can cause a surface layer to be produced on the elongated metal substrate.
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[0067] The surface layer can include stable, or otherwise suitable, phases
or modified
layers of a base-metal of the alloy of the elongated metal substrate. In an
example in which
the elongated metal substrate includes an aluminum alloy, the stable phase may
include an
aluminum oxide or a hydrolyzed aluminum oxide phase (e.g., boehmite, diaspore,
etc.). The
stable phase may be present as a surface layer and may optionally increase the
corrosion-
resistance, adhesion to subsequent coatings, or the bond durability
performance indicators
associated with the elongated metal substrate. In some examples, the super-
heated steam can
include additives such as the inhibitors described above. The inhibitors can
combine with the
stable phase of the surface layer and can further increase characteristics or
other suitable
performance indicators of the elongated metal substrate. For example, the
inhibitors and the
stable phase can be deposited simultaneously by the steam nozzles 402 and the
nozzle boxes
404 for increasing the performance indicators of the elongated metal
substrate.
[0068] The nozzle boxes 404 can include nozzles separate from the steam
nozzle 402, can
include natural gas burners, or can include other suitable components for the
nozzle boxes
404. The nozzle boxes 404 can provide heat to the elongated metal substrate
105, for
example, via the super-heated steam, the heat from burning the natural gas, or
other suitable
heat source. While four steam nozzles 402 and four nozzle boxes 404 are
illustrated, any
suitable amount of steam nozzles 402 and nozzle boxes 404 can be included in
the furnace, or
in any portion or sub-part thereof, for simultaneously solution heat treating
or continuous
annealing and surface treating the elongated metal substrate.
[0069] In some examples, the furnace can include more than one zone. For
example, the
components 400 illustrated in FIG. 4 can be included in a first zone, and a
second zone can
include a second set of components, etc. The furnace can include any suitable
amount of
zones. For example, the furnace can include nine zones, 10 zones, 11 zones, 12
zones, or
other suitable amount of zones for performing the simultaneous solution heat
treatment or
continuous annealing and surface treatment operation. Optionally, cleaning the
elongated
metal substrate, such as by using hot water, alkaline cleaners, or the like,
may be performed
prior to a solution heat treatment or continuous annealing operation. In some
examples, one
or more zones within a furnace may be used for cleaning, such as to remove
oil, soil, dirt,
dust, debris, or the like from the surface. After a cleaning process,
simultaneous surface
treatment and solution heat treatment or continuous annealing may be
performed.
[0070] FIG. 5 provides a flowchart of a process 500 to create a processed
metal product
by simultaneously performing solution heat treatment or continuous annealing
and surface
treatment operations using super-heated steam. At block 502, an elongated
metal substrate is
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subjected to a solution heat treatment operation or continuous annealing
operation. And, at
block 504, the elongated metal substrate is subjected to a surface treatment
operation. In
some examples, the solution heat treatment or continuous annealing process of
the block 502
and the surface treatment operation of the block 504 can be performed
simultaneously.
[0071] In some example, the solution heat treatment or continuous annealing
process of
the block 502 and the surface treatment operation of the block 504 can be
performed using
super-heated steam using a furnace (e.g., using the steam nozzles 402), using
a flame
pyrolysis operation (e.g., using the flame pyrolysis source 335), or using
other suitable
techniques. The super-heated steam can be applied to a surface of the
elongated metal
substrate to produce a surface layer of the elongated metal substrate. The
surface layer can
include one or more stable phases or layers of a base-metal of the elongated
metal substrate.
For example, if the elongated metal substrate includes an aluminum alloy, the
stable phases
included in the surface layer can include boehmite (y ¨ A100 H), diaspore (a ¨
A100H), or
other suitable stable phases of aluminum.
[0072] At block 506, the elongated metal substrate is optionally subjected
to a quenching
solution. The quenching solution can include pure water, water with additives,
or other
suitable quenching solutions. The quenching solution can be used to cool the
elongated metal
substrate subsequent to the simultaneous solution heat treatment or continuous
annealing and
surface treatment operation while retaining the surface layer (and other
performance indicator
improvements) produced by the operations of the blocks 502 and 504.
[0073] In some examples, additives can be included in the super-heated
steam, the
quenching solution, or in other mediums to which the elongated metal substrate
can be
subjected. The additives can include one or more inhibitors, organic surface
enhancers,
inorganic surface enhancers, or other suitable additives. The inhibitors can
include Mn, Ce,
Zr, Mo, acids, or other suitable inhibiting elements or compounds. The organic
and inorganic
surface enhancers can include phosphates, silicates, silanes, or other
suitable organic or
inorganic surface enhancers. The additives can be included in the super-heated
steam, the
quenching solution, in other mediums to which the elongated metal substrate
can be
subjected, or a combination thereof for combining with the stable phases of
the surface layer
or for otherwise improving performance indicators (e.g., corrosion resistance,
bond
durability, etc.) of the elongated metal substrate.
[0074] FIG. 6 provides a sectional side-view of a processed metal product
600 having a
surface layer 602 that can be created by simultaneously performing solution
heat treatment or
continuous annealing and surface treatment operations with respect to the
processed metal
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product. The processed metal product 600 can additionally include a substrate
604 that can be
a portion of the elongated metal substrate 105. The substrate 604 can include
a metal alloy
such as an aluminum alloy. The surface layer 602 can include one or more
stable phases of
the base-metal of the substrate 604. In an example in which the substrate 604
includes an
aluminum alloy, the surface layer 602 can include stable phases of aluminum
(e.g., boehmite,
diaspore, and corundum, etc.). The surface layer 602 can additionally include
inhibitors or
other surface enhancers. For example, the super-heated steam and quenching
solution applied
to the elongated metal substrate during the simultaneous solution heat
treatment or
continuous annealing and surface treatment operation can include inhibitors
(e.g., Mn, Ce, Zr,
Mo, acids, etc.), surface enhancers (e.g., phosphates, silicates, silanes,
etc.), or a combination
thereof. The inhibitors and surface enhancers can combine with, or be applied
to the
elongated metal substrate simultaneously with respect to, the stable phases
for improving
performance indicators or characteristics with respect to the processed metal
product 600.
[0075] The substrate 604 can include an aluminum alloy or other suitable
substrate
material. For example, the substrate 604 can include a 2xxx alloy, a 5xxx
alloy, a 6xxx alloy,
a 7xxx alloy, or other suitable alloy for the substrate 604. Additionally, the
surface layer 602
can be produced on the substrate 604 and a thickness of the surface layer 602
can be from 10
nm to 500 nm. For example, the surface layer 602 can be from 10 nm to 450 nm,
from 10 nm
to 400 nm, from 10 nm to 350 nm, from 10 nm to 300 nm, from 10 nm to 250 nm,
from 10
nm to 200 nm, from 10 nm to 150 nm, from 10 nm to 100 nm, from 10 nm to 50 nm,
from 50
nm to 100 nm, from 100 nm to 150 nm, from 150 nm to 200 nm, from 200 nm to 250
nm,
from 250 nm to 300 nm, from 300 nm to 350 nm, from 350 nm to 400 nm, from 400
nm to
450 nm, from 450 nm to 500 nm, or other suitable range from 10 nm to 500 nm.
Methods of Using Metal Products
[0076] The aluminum alloy products described herein can be used in
automotive
applications and other transportation applications, including aircraft and
railway applications.
For example, the disclosed aluminum alloy products can be used to prepare
automotive
structural parts, such as bumpers, side beams, roof b eams, cross beams,
pillar reinforcements
(e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side
panels, inner hoods,
outer hoods, or trunk lid panels. The aluminum alloy products and methods
described herein
can also be used in aircraft or railway vehicle applications, to prepare, for
example, external
and internal panels.
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[0077] 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.
Methods of Treating Metals andMetal Alloys
[0078] Described herein are methods of treating metals and metal alloys,
including
aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites,
and
steel, among others, and the resultant treated metals and metal alloys. In
some examples, the
metals for use in the methods described herein include aluminum alloys, for
example, lxxx
series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum
alloys, 4xxx
series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum
alloys, 7xxx
series aluminum alloys, or 8xxx series aluminum alloys. In some examples, the
materials for
use in the methods described herein include non-ferrous materials, including
aluminum,
aluminum alloys, magnesium, magnesium-based materials, magnesium alloys,
magnesium
composites, titanium, titanium-based materials, titanium alloys, copper,
copper-based
materials, composites, sheets used in composites, or any other suitable metal,
non-metal or
combination of materials. 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
described herein. In some examples, aluminum alloys containing iron are useful
with the
methods described herein.
[0079] By way of non-limiting example, exemplary lxxx series aluminum
alloys for use
in the methods described herein can include AA1100, AA1100A, AA1200, AA1200A,
AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145,AA1345,
AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185,AA1285,
AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.
[0080] Non-limiting exemplary 2xxx series aluminum alloys for use in the
methods
described herein can include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007,
AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111,
AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016,
AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319,
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AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224,
AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026,
AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032,
AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044,
AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090,
AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197,
AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.
[0081] Non-limiting exemplary 3xxx series aluminum alloys for use in the
methods
described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B,
AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A,
AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009,
AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015,AA3016,
AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.
[0082] Non-limiting exemplary 4xxx series aluminum 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.
[0083] Non-limiting exemplary 5xxx series aluminum alloys for use in the
methods
described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205,
AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210,
AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A,
AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140,
AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A,
AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251,
AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B,
AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854,
AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556,
AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059,
AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283,
AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or
AA5088.
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[0084] Non-limiting exemplary 6xxx series aluminum 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, 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, AA6963, AA6064,
AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A,
AA6082, AA6082A, AA6182, AA6091, or AA6092.
[0085] Non-limiting exemplary 7xxx series aluminum alloys for use in the
methods
described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072,
AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024,
AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A,
AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016,
AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033,
AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A,
AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250,
AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168,
AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185,
AA7090, AA7093, AA7095, or AA7099.
[0086] Non-limiting exemplary 8xxx series aluminum alloys for use in the
methods
described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011,
AA8011A, AA8111,AA8211, AA8112, AA8014, AA8015, AA8016, AA8017,AA8018,
AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026,
AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077,
AA8177, AA8079, AA8090, AA8091, or AA8093.
[0087] 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
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suggest themselves to those skilled in the art without departing from the
spirit of the
invention. The examples and embodiments described herein may also make use of
conventional procedures, unless otherwise stated. Some of the procedures are
described
herein for illustrative purposes.
ILLUSTRATIVE ASPECTS
[0088] As used below, any reference to a series of aspects (e.g., "Aspects
1-4") or non-
enumerated group of aspects (e.g., "any previous or subsequent aspect") is to
be understood
as a reference to each of those aspects disjunctively (e.g., "Aspects 1-4" is
to be understood
as "Aspects 1, 2, 3, or 4 ").
[0089] Aspect 1 is a method of comprising: subjecting an elongated metal
substrate to a
solution heat treatment process or a continuous annealing process; and
subjecting the
elongated metal substrate to a surface treatment process, wherein the surface
treatment
process and the solution heat treatment process or continuous annealing
process are
performed simultaneously using super-heated steam, thereby generating a
processed metal
product.
[0090] Aspect 2 is the method of any previous or subsequent aspect, wherein
the
elongated metal substrate comprises an aluminum alloy sheet metal or a coil of
an aluminum
alloy sheet metal.
[0091] Aspect 3 is the method of any previous or subsequent aspect, wherein
the
aluminum alloy sheet metal includes one of a 2xxx aluminum alloy, a 5xxx
aluminum alloy,
a 6xxx aluminum alloy, or a 7xxx aluminum alloy.
[0092] Aspect 4 is the method of any previous or subsequent aspect, further
comprising
quenching the elongated metal substrate using a quenchant comprising water and
at least one
of Mn, Ce, Zr, Mo, a silicate, a silane, or a sealant, wherein the processed
metal product
includes a surface layer comprising at least one of Mn, Ce, Zr, Mo, the
silicate, the silane, or
the sealant.
[0093] Aspect 5 is the method of any previous or subsequent aspect, wherein
the super-
heated steam includes an inhibiting material, wherein the inhibiting material
comprises at
least one of Mn, Ce, Zr, or Mo, and wherein at least one of Mn, Ce, Zr, or Mo
is incorporated
on a surface layer of the processed metal product.
[0094] Aspect 6 is the method of any previous or subsequent aspect, wherein
the
processed metal product includes a surface layer formed by the solution heat
treatment
process or continuous annealing process and the surface treatment process,
wherein the
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surface layer includes at least one of boehmite, bayerite, diaspore, or
corundum, and wherein
a thickness of the surface layer is from 10 nm to 500 nm.
[0095] Aspect 7 is the method of any previous or subsequent aspect, wherein
a moisture
content of the super-heated steam is less than or equal to 10%.
[0096] Aspect 8 is the method of any previous or subsequent aspect, wherein
subjecting
the elongated metal substrate to the solution heat treatment process or
continuous annealing
process and subjecting the elongated metal substrate to the surface treatment
process includes
passing the elongated metal substrate into a furnace, and wherein the furnace
includes one or
more nozzles for spraying super-heated steam onto the elongated metal
substrate.
[0097] Aspect 9 is the method of any previous or subsequent aspect, wherein
the
elongated metal substrate comprises an aluminum alloy sheet metal tube.
[0098] Aspect 10 is the method of any previous or subsequent aspect,
further comprising
preparing the aluminum alloy sheet metal tube by: roll-forming an aluminum
alloy sheet
metal into a tubular shape; and welding edges of the tubular shape together to
enclose the
aluminum alloy sheet metal tube.
[0099] Aspect 11 is the method of any previous or subsequent aspect,
wherein the
aluminum alloy sheet metal tube has a circular or non-circular cross-sectional
shape.
[0100] Aspect 12 is the method of any previous or subsequent aspect,
wherein the
solution heat treatment process or continuous annealing process and the
surface treatment
process are performed using a combination of flame pyrolysis and induction
heating.
[0101] Aspect 13 is the method of any previous or subsequent aspect,
wherein the
solution heat treatment process or continuous annealing process and the
surface treatment
process are performed subsequent to welding the elongated metal substrate to
form a metal
tube.
[0102] Aspect 14 is a metal product comprising: an aluminum alloy sheet
metal substrate;
and a surface layer on the aluminum alloy sheet metal substrate, wherein the
surface layer
includes at least one of boehmite, bayerite, diaspore, and corundum, and
wherein a thickness
of the surface layer is from 10 nm to 500 nm.
[0103] Aspect 15 is the metal product of any previous or subsequent aspect,
wherein the
aluminum alloy sheet metal substrate includes one of a 2xxx aluminum alloy, a
6xxx
aluminum alloy, or a 7xxx aluminum alloy.
[0104] Aspect 16 is the metal product of any previous or subsequent aspect,
wherein the
aluminum alloy sheet metal substrate comprises a solution heat treated
aluminum alloy sheet
metal substrate or a continuously annealed aluminum alloy sheet metal
substrate.
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[0105] Aspect 17 is the metal product of any previous or subsequent aspect,
wherein the
surface layer includes at least one of Mn, Ce, Zr, Mo, a silicate, a silane,
or a sealant.
[0106] Aspect 18 is the metal product of any previous or subsequent aspect,
wherein the
surface layer is generated by subjecting the aluminum alloy sheet metal
substrate to super-
heated steam characterized by a moisture content of less than or equal to 10%.
[0107] Aspect 19 is the metal product of any previous or subsequent aspect,
wherein the
super-heated steam includes an inhibiting material, wherein the inhibiting
material includes at
least one of Mn, Ce, Zr, and Mo.
[0108] Aspect 20 is the metal product of any previous or subsequent aspect,
wherein the
surface layer is, at least in part, generated by exposing the aluminum alloy
sheet metal
substrate to an aqueous quenchant.
[0109] Aspect 21 is the metal product of any previous or subsequent aspect,
wherein the
aqueous quenchant includes water and at least one of Mn, Ce, Zr, Mo, a
silicate, a silane, or a
sealant.
[0110] Aspect 22 is the metal product of any previous or subsequent aspect,
wherein the
metal product exhibits a bond durability of from 30 cycles to 65 cycles or
more according to
an ASTM D3762 standard test or a FLTM BV 101-07 standard test.
[0111] Aspect 23 is a tubular metal product comprising: a roll-formed
aluminum alloy
sheet metal tube; and a surface layer on the roll-formed aluminum alloy sheet
metal tube,
wherein the surface layer includes at least one of boehmite, bayerite,
diaspore, and corundum,
and wherein the surface layer is between 10 nm and 500 nm.
[0112] Aspect 24 is the tubular metal product of any previous or subsequent
aspect,
wherein the roll-formed aluminum alloy sheet metal tube includes one of a 2xxx
aluminum
alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.
[0113] Aspect 25 is the tubular metal product of any previous or subsequent
aspect,
wherein the surface layer includes at least one of Mn, Ce, Zr, Mo, a silicate,
a silane, or a
sealant.
[0114] Aspect 26 is the tubular metal product of any previous or subsequent
aspect,
wherein the roll-formed aluminum alloy sheet metal tube is prepared by: roll-
forming an
aluminum alloy sheet metal into a tubular shape; and welding edges of the
tubular shape
together to enclose the roll-formed aluminum alloy sheet metal tube.
[0115] Aspect 27 is the tubular metal product of any previous or subsequent
aspect,
wherein the roll-formed aluminum alloy sheet metal tube comprises a treated
aluminum alloy
sheet metal tube, subjected to simultaneous solution heat treatment or
continuous annealing
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and surface treatment process using a combination of flame pyrolysis and
induction heating
subsequent to welding the edges of the tubular shape together.
[0116] Aspect 28 is the tubular metal product of any previous or subsequent
aspect,
wherein the metal product exhibits a bond durability of from 30 cycles to 65
cycles or more
according to an ASTM D3762 standard test or a FLTM BV 101-07 standard test.
[0117] Aspect 28 is the tubular metal product of any previous or subsequent
aspect,
wherein the wherein the roll-formed aluminum alloy sheet metal tube has a
circular or non-
circular cross-sectional shape.
