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EP3652356B1 - Alliage d'aluminium résistant à la corrosion, à résistance élevée, et procédé de fabrication associé - Google Patents

Alliage d'aluminium résistant à la corrosion, à résistance élevée, et procédé de fabrication associé Download PDF

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Publication number
EP3652356B1
EP3652356B1 EP17739842.7A EP17739842A EP3652356B1 EP 3652356 B1 EP3652356 B1 EP 3652356B1 EP 17739842 A EP17739842 A EP 17739842A EP 3652356 B1 EP3652356 B1 EP 3652356B1
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Prior art keywords
aluminum alloy
alloy
ratio
alloys
aluminum
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German (de)
English (en)
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EP3652356A1 (fr
Inventor
Sazol Kumar DAS
Hany Ahmed
Wei Wen
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Novelis Inc Canada
Novelis Inc
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Novelis Inc Canada
Novelis Inc
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions

Definitions

  • the present disclosure relates to aluminum alloys and methods of making and processing the same.
  • the present disclosure further relates to aluminum alloys exhibiting high mechanical strength, formability, and corrosion resistance.
  • Recyclable aluminum alloys with high strength are desirable for improved product performance in many applications, including transportation (encompassing without limitation, e.g., trucks, trailers, trains, and marine) applications, electronics applications, and automobile applications.
  • transportation encompassing without limitation, e.g., trucks, trailers, trains, and marine
  • a high-strength aluminum alloy in trucks or trailers would be lighter than conventional steel alloys, providing significant emission reductions that are needed to meet new, stricter government regulations on emissions.
  • Such alloys should exhibit high strength, high formability, and corrosion resistance. Further, it is desirable for such alloys to be formed from recycled content.
  • aluminum alloys comprising 0.25 - 1.3 wt. % Si, 1.0 - 2.5 wt. % Mg, 0.5 - 1.5 wt. % Cu, up to 0.2 wt. % Fe, up to 3.0 wt. % Zn, up to 0.15 wt. % Zr, up to 0.5 wt. % Mn, up to 0.15 wt. % impurities, with the remainder as Al, wherein a ratio of Mg to Si (Mg/Si ratio) is from 1.5 to 1 to 3.5 to 1.
  • the aluminum alloys can comprise 0.55 - 1.1 wt. % Si, 1.25 - 2.25 wt.
  • the aluminum alloys can comprise 0.65 - 1.0 wt. % Si, 1.5 - 2.25 wt. % Mg, 0.6 - 1.0 wt. % Cu, 0.12 - 0.17 wt. % Fe, 2.0 - 3.0 wt. % Zn, up to 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can comprise 0.65 - 1.0 wt. % Si, 1.5 - 2.25 wt. % Mg, 0.6 - 1.0 wt. % Cu, 0.12 - 0.17 wt. % Fe, 2.0 - 3.0 wt. % Zn, up to 0.15 wt. % impurities, with the remainder as Al.
  • the ratio of Mg to Si is from 1.5 to 1 to 3.5 to 1.
  • the Mg/Si ratio can be from 2.0 to 1 to 3.0 to 1.
  • the ratio of Zn to the Mg/Si ratio i.e., the Zn/(Mg/Si) ratio
  • the Zn/(Mg/Si) ratio is from 0.75 to 1 to 1.4 to 1.
  • the Zn/(Mg/Si) ratio can be from 0.8 to 1 to 1.1 to 1.
  • the ratio of Cu to the Zn/(Mg/Si) ratio i.e., the Cu/[Zn/(Mg/Si)] ratio
  • the Cu/[Zn/(Mg/Si)] ratio is from 0.8 to 1 to 1.1 to 1.
  • the aluminum alloy product can have a yield strength of at least 340 MPa (e.g., from 360 MPa to 380 MPa) in the T6 temper.
  • the aluminum alloy products described herein are corrosion resistant and can have an average intergranular corrosion pit depth of less than 100 ⁇ m in the T6 temper.
  • the aluminum alloy products also display excellent bendability and can have an r/t (bendability) ratio of 0.5 or less in the T4 temper.
  • the aluminum alloy product comprises one or more precipitates selected from the group consisting of MgZn 2 / Mg(Zn,Cu) 2 , Mg 2 Si, and Al 4 Mg 8 Si 7 Cu 2 .
  • the aluminum alloy product can comprise MgZn 2 / Mg(Zn,Cu) 2 in an average amount of at least 300,000,000 particles per mm 2 , Mg 2 Si in an average amount of at least 600,000,000 particles per mm 2 , and/or Al 4 Mg 8 Si 7 Cu 2 in an average amount of at least 600,000,000 particles per mm 2 .
  • the aluminum alloy product comprises MgZn 2 / Mg(Zn,Cu) 2 , Mg 2 Si, and Al 4 Mg 8 Si 7 Cu 2 .
  • a ratio of Mg 2 Si to Al 4 Mg 8 Si 7 Cu 2 can be from 1:1 to 1.5:1, a ratio of Mg 2 Si to MgZn 2 / Mg(Zn,Cu) 2 can be from 1.5:1 to 3:1, and a ratio of Al 4 Mg 8 Si 7 Cu 2 to MgZn 2 / Mg(Zn,Cu) 2 can be from 1.5:1 to 3:1.
  • the method comprises casting an aluminum alloy as described herein to form an aluminum alloy cast product, homogenizing the aluminum alloy cast product, hot rolling the homogenized aluminum alloy cast product to provide a final gauge aluminum alloy, and solution heat treating the final gauge aluminum alloy.
  • the method can further comprise pre-aging the final gauge aluminum alloy.
  • the aluminum alloy is cast from a molten aluminum alloy comprising scrap metal, such as from scrap metal containing a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a combination of these.
  • Described herein are high-strength aluminum alloys and methods of making and processing such alloys.
  • the aluminum alloys described herein exhibit improved mechanical strength, deformability, and corrosion resistance properties.
  • the aluminum alloys can be prepared from recycled materials.
  • Aluminum alloy products prepared from the alloys described herein include precipitates to enhance strength, such as MgZn 2 / Mg(Zn,Cu) 2 , Mg 2 Si, and Al 4 Mg 8 Si 7 Cu 2 .
  • a plate generally has a thickness of greater than about 6 mm.
  • a plate may refer to an aluminum product having a thickness of greater than 6 mm, greater than 10 mm, greater than 15 mm, greater than 20 mm, greater than 25 mm, greater than 30 mm, greater than 35 mm, greater than 40 mm, greater than 45 mm, greater than 50 mm, or greater than 100 mm.
  • slab indicates an alloy thickness in a range of approximately 5 mm to approximately 50 mm.
  • a slab may have a thickness of 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, or 50 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm.
  • a shate may have a thickness of 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.
  • a sheet generally refers to an aluminum product having a thickness of less than about 4 mm.
  • a sheet may have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm.
  • An F condition or temper refers to an aluminum alloy as fabricated.
  • An O condition or temper refers to an aluminum alloy after annealing.
  • a T4 condition or temper refers to an aluminum alloy after solution heat treatment (SHT) (i.e., solutionization) followed by natural aging.
  • a T6 condition or temper refers to an aluminum alloy after solution heat treatment followed by artificial aging (AA).
  • a T8x condition or temper refers to an aluminum alloy after solution heat treatment, followed by cold working and then by artificial aging.
  • cast metal article As used herein, terms such as "cast metal article,” “cast article,” 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.
  • room temperature can include a temperature of from 15 °C to 30 °C, for example 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.
  • the following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %) based on the total weight of the alloy. The remainder of each alloy is aluminum, with a maximum wt. % of 0.15 % for the sum of the impurities.
  • novel aluminum alloys exhibit high strength, high formability, and corrosion resistance.
  • the properties of the alloys are achieved due to the elemental compositions of the alloys as well as the methods of processing the alloys to produce aluminum alloy products, including sheets, plates, and shates.
  • the alloy has a Cu content of from 0.5 wt. % to 1.5 wt. %, a Zr content of from 0.07 wt. % to 0.12 wt. %, and a controlled Si to Mg ratio, as further described below.
  • the alloys can have the following elemental composition as provided in Table 1: Table 1 Element Weight Percentage (wt. %) Si 0.25 - 1.3 Fe 0 - 0.2 Mn 0 - 0.5 Mg 1.0 - 2.5 Cu 0.5 - 1.5 Zn 0-3.0 Zr 0-0.15 Others 0 - 0.05 (each) 0 - 0.15 (total) Al Remainder
  • the alloys can have the following elemental composition as provided in Table 2.
  • Table 2 Element Weight Percentage (wt. %) Si 0.55 - 1.1 Fe 0.05-0.17 Mn 0.05 - 0.3 Mg 1.25-2.25 Cu 0.6 - 1.0 Zn 1.5 - 3.0 Zr 0.09 - 0.12 Others 0 - 0.05 (each) 0 - 0.15 (total) Al Remainder
  • the alloys can have the following elemental composition as provided in Table 3.
  • Table 3 Element Weight Percentage (wt. %) Si 0.65 - 1.0 Fe 0.12-0.17 Mn 0.05 - 0.2 Mg 1.5 - 2.25 Cu 0.6 - 1.0 Zn 2.0 - 3.0 Zr 0.08 - 0.11 Others 0 - 0.05 (each) 0 - 0.15 (total) Al Remainder
  • the disclosed alloy includes silicon (Si) in an amount from 0.25 % to 1.3 % (e.g., from 0.55 % to 1.1 % or from 0.65 % to 1.0 %) based on the total weight of the alloy.
  • the alloy can include 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.4 % ,0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.5 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.6 %, 0.61 %, 0.62
  • the alloy described herein includes iron (Fe) in an amount up to 0.2 % (e.g., from 0.05 % to 0.17 % or from 0.12 % to 0.17 %) based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.2 % Fe.
  • Fe is not present in the alloy (i.e., 0 %). All percentages are expressed in wt. %.
  • the alloy described herein includes manganese (Mn) in an amount up to 0.5 % (e.g., from 0.05 % to 0.3 % or from 0.05 % to 0.2 %) based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.2 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %,
  • the disclosed alloy includes magnesium (Mg) in an amount from 1.0 % to 2.5 % (e.g., from 1.25 % to 2.25 % or from 1.5 % to 2.25 %) based on the total weight of the alloy.
  • the alloy can include 1.0 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, 1.1 %, 1.11 %, 1.12 %, 1.13 %, 1.14 %, 1.15 %, 1.16 %, 1.17 %, 1.18 %, 1.19 %, 1.2 %, 1.21 %, 1.22 %, 1.23 %, 1.24 %, 1.25 %, 1.26 %, 1.27 %, 1.28 %, 1.29 %, 1.3 %, 1.31 %, 1.32 %, 1.33 %, 1.34 %, 1.35 %, 1.36 %, 1.37 %, 1.
  • the disclosed alloy includes copper (Cu) in an amount from 0.5 % to 1.5 % (e.g., from 0.6 % to 1.0 % or from 0.6 % to 0.9 %) based on the total weight of the alloy.
  • the alloy can include 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.
  • the alloy described herein includes zinc (Zn) in an amount up to 3.0 % (e.g., from 1.0 % to 3.0 %, from 1.5 % to 3.0 %, or from 2.0 % to 3.0 %) based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.2 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.4 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.5
  • zirconium can be included in the alloys described herein.
  • the alloy includes Zr in an amount up to 0.15 % (e.g., from 0.07 % to 0.15 %, from 0.09 % to 0.12 %, or from 0.08 % to 0.11 %) based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, or 0.15 % Zr.
  • Zr is not present in the alloys (i.e., 0 %). All percentages are expressed in wt. %. In certain aspects, Zr is added to the above-described compositions to form (Al,Si) 3 Zr dispersoids (DO 22 /DO 23 dispersoids) and/or Al 3 Zr dispersoids (L1 2 dispersoids).
  • the alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below each.
  • impurities may include, but are not limited to, Ga, V, Ni, Sc, Ag, B, Bi, Li, Pb, Sn, Ca, Cr, Ti, Hf, Sr, or combinations thereof.
  • Ga, V, Ni, Sc, Ag, B, Bi, Li, Pb, Sn, Ca, Cr, Ti, Hf, or Sr may be present in an alloy 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 does not exceed 0.15 % (e.g., 0.1 %). All percentages are expressed in wt. %.
  • the remaining percentage of the alloy is aluminum.
  • Suitable exemplary alloys can include, for example, 1.0 % Si, 2.0 % - 2.25 % Mg, 0.6 % - 0.7 % Cu, 2.5 % - 3.0 % Zn, 0.07 - 0.10 % Mn, 0.14 - 0.17 % Fe, 0.09 - 0.10 % Zr, and up to 0.15 % total impurities, with the remainder Al.
  • suitable exemplary alloys can include 0.55 % - 0.65 % Si, 1.5 % Mg, 0.7 % - 0.8 % Cu, 1.55 % Zn, 0.14 - 0.15 % Mn, 0.16 - 0.18 % Fe, and up to 0.15 % total impurities, with the remainder Al.
  • suitable exemplary alloys can include 0.65 % Si, 1.5 % Mg, 1.0 % Cu, 2.0 % - 3.0 % Zn, 0.14 - 0.15 % Mn, 0.17 % Fe, and up to 0.15 % total impurities, with the remainder Al.
  • the Cu, Mg, and Si ratios and Zn content are controlled to enhance corrosion resistance, strength, and formability.
  • the Zn content can control corrosion morphology as described below, by, for example, inducing pitting corrosion and suppressing intergranular corrosion (IGC).
  • the ratio of Mg to Si is from 1.5:1 to 3.5:1 (e.g., from 1.75:1 to 3.0:1 or from 2.0:1 to 3.0:1).
  • the Mg/Si ratio can be 1.5:1, 1.6:1, 1.7:1, 1.8:1, 1.9:1, 2.0:1, 2.1:1, 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1, 3.0:1, 3.1:1, 3.2:1, 3.3:1, 3.4:1, 3.5:1, 3.6:1, 3.7:1, 3.8:1, 3.9:1, or 4.0:1.
  • an aluminum alloy having an Mg/Si ratio of 1.5:1 to 3.5:1 can exhibit high strength and increased formability.
  • an aluminum alloy having an Mg/Si ratio of 2.0:1 - 3.0:1 and a Zn content of 2.5 wt. % - 3.0 wt. % can exhibit suppression of IGC typically observed in aluminum alloys having Mg and Si as predominant alloying elements, and instead can induce pitting corrosion.
  • pitting corrosion can be favorable over IGC due to a limited attack depth, as IGC can occur along grain boundaries and propagate deeper into the aluminum alloy than pitting corrosion.
  • a ratio of Zn to the ratio of Mg/Si can be from 0.75:1 to 1.4:1 (e.g., from 0.8:1 to 1.1:1).
  • the Zn/(Mg/Si) ratio can be 0.75:1, 0.8:1, 0.85:1, 0.9:1, 0.95:1, 1.0:1, 1.05:1, 1.1:1, 1.15:1, 1.2:1, 1.25:1, 1.3:1, 1.35:1, or 1.4:1.
  • a ratio of Cu to the Zn/(Mg/Si) ratio can be from 0.7:1 to 1.4:1 (e.g., the Cu/[Zn/(Mg/Si)] ratio can be 0.8:1 to 1.1:1).
  • the ratio of Cu/[Zn/(Mg/Si)] can be 0.7:1, 0.75:1, 0.8:1, 0.85:1, 0.9:1, 0.95:1, 1.0:1, 1.05:1, 1.1:1, 1.15:1, 1.2:1, 1.25:1, 1.3:1, 1.35:1, or 1.4:1.
  • the ratio of Cu/[Zn/(Mg/Si)] can provide high strength, high deformability, and high corrosion resistance.
  • Cu, Si, and Mg can form precipitates in the alloy to result in an alloy with higher strength and enhanced corrosion resistance. These precipitates can form during the aging processes, after solution heat treatment.
  • the Mg and Cu content can provide precipitation of an M / ⁇ phase or M phase (e.g., MgZn 2 / Mg(Zn,Cu) 2 ), resulting in precipitates that can increase strength in the aluminum alloy.
  • MgZn 2 / Mg(Zn,Cu) 2 metastable Guinier Preston (GP) zones can form, which in turn transfer to ⁇ " needle shape precipitates (e.g., magnesium silicide, Mg 2 Si) that contribute to precipitation strengthening of the disclosed alloys.
  • GP metastable Guinier Preston
  • addition of Cu leads to the formation of lathe-shaped L phase precipitation (e.g., Al 4 Mg 8 Si 7 Cu 2 ), which is a precursor of Q' precipitate phase formation and which further contributes to strength.
  • the M phase precipitates can be present in the aluminum alloy in an average amount of at least 300,000,000 particles per square millimeter (mm 2 ).
  • the M phase precipitates can be present in an amount of at least 310,000,000 particles per mm 2 , at least 320,000,000 particles per mm 2 , at least 330,000,000 particles per mm 2 , at least 340,000,000 particles per mm 2 , at least 350,000,000 particles per mm 2 , at least 360,000,000 particles per mm 2 , at least 370,000,000 particles per mm 2 , at least 380,000,000 particles per mm 2 , at least 390,000,000 particles per mm 2 , or at least 400,000,000 particles per mm 2 .
  • the L phase precipitates can be present in the aluminum alloy in an average amount of at least 600,000,000 particles per square millimeter (mm 2 ).
  • the L phase precipitates can be present in an amount of at least 610,000,000 particles per mm 2 , at least 620,000,000 particles per mm 2 , at least 630,000,000 particles per mm 2 , at least 640,000,000 particles per mm 2 , at least 650,000,000 particles per mm 2 , at least 660,000,000 particles per mm 2 , at least 670,000,000 particles per mm 2 , at least 680,000,000 particles per mm 2 , at least 690,000,000 particles per mm 2 , or at least 700,000,000 particles per mm 2 .
  • the ⁇ " phase precipitates can be present in the aluminum alloy in an average amount of at least 600,000,000 particles per square millimeter (mm 2 ).
  • the ⁇ " phase precipitates can be present in an amount of at least 610,000,000 particles per mm 2 , at least 620,000,000 particles per mm 2 , at least 630,000,000 particles per mm 2 , at least 640,000,000 particles per mm 2 , at least 650,000,000 particles per mm 2 , at least 660,000,000 particles per mm 2 , at least 670,000,000 particles per mm 2 , at least 680,000,000 particles per mm 2 , at least 690,000,000 particles per mm 2 , at least 700,000,000 particles per mm 2 , at least 710,000,000 particles per mm 2 , at least 720,000,000 particles per mm 2 , at least 730,000,000 particles per mm 2 , at least 740,000,000 particles per mm 2 , or at least 750,000,000 particles per mm 2 .
  • a ratio of the ⁇ " phase precipitates (e.g., Mg 2 Si) to the L phase precipitates (e.g., Al 4 Mg 8 Si 7 Cu 2 ) can be from 1:1 to 1.5:1 (e.g., from 1.1:1 to 1.4:1).
  • the ratio of the ⁇ " phase precipitates to the L phase precipitates can be 1:1, 1.1:1, 1.2:1, 1.3:1, 1.4:1, or 1.5:1.
  • a ratio of the ⁇ " phase precipitates (e.g., Mg 2 Si) to the M phase precipitates (e.g., MgZn 2 and/or Mg(Zn,Cu) 2 ) can be from 1.5:1 to 3:1 (e.g., from 1.6:1 to 2.8:1 or from 2.0:1 to 2.5:1).
  • the ratio of the ⁇ " phase precipitates to the M phase precipitates can be 1.5:1, 1.6:1, 1.7:1, 1.8:1, 1.9:1, 2.0:1, 2.1:1, 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1, or 3.0:1.
  • a ratio of the L phase precipitates (e.g., Al 4 Mg 8 Si 7 Cu 2 ) to the M phase precipitates (e.g., MgZn 2 and/or Mg(Zn,Cu) 2 ) can be from 1.5:1 to 3:1 (e.g., from 1.6:1 to 2.8:1 or from 2.0:1 to 2.5:1).
  • the ratio of the L phase precipitates to the M phase precipitates can be 1.5:1, 1.6:1, 1.7:1, 1.8:1, 1.9:1, 2.0:1, 2.1:1, 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1, or 3.0:1.
  • the alloys described herein display exceptional mechanical properties, as further provided below.
  • the mechanical properties of the aluminum alloys can be further controlled by various aging conditions depending on the desired use.
  • the alloy can be produced (or provided) in the T4 temper or the T6 temper.
  • T4 aluminum alloy articles that are solution heat-treated and naturally aged can be provided. These T4 aluminum alloy articles can optionally be subjected to additional aging treatment(s) to meet strength requirements upon receipt.
  • aluminum alloy articles can be delivered in other tempers, such as the T6 temper, by subjecting the T4 alloy material to the appropriate aging treatment as described herein or otherwise known to those of skill in the art. Exemplary properties in exemplary tempers are provided below.
  • the aluminum alloy can have a yield strength of at least 340 MPa in the T6 temper.
  • the yield strength can be at least 350 MPa, at least 360 MPa, or at least 370 MPa.
  • the yield strength is from 340 MPa to 400 MPa.
  • the yield strength can be from 350 MPa to 390 MPa or from 360 MPa to 380 MPa.
  • the aluminum alloy can have an ultimate tensile strength of at least 400 MPa in the T6 temper.
  • the ultimate tensile strength can be at least 410 MPa, at least 420 MPa, or at least 430 MPa.
  • the ultimate tensile strength is from 400 MPa to 450 MPa.
  • the ultimate tensile strength can be from 410 MPa to 440 MPa or from 415 MPa to 435 MPa.
  • the aluminum alloy has sufficient ductility or toughness to meet a 90° bendability of 1.0 or less in the T4 temper (e.g., 0.5 or less).
  • the r/t bendability ratio is 1.0 or less, 0.9 or less, 0.8 or less, 0.7 or less, 0.6 or less, 0.5 or less, 0.4 or less, 0.3 or less, 0.2 or less, or 0.1 or less, where r is the radius of the tool (die) used and t is the thickness of the material.
  • the aluminum alloy exhibits a uniform elongation of greater than or equal to 20 % in the T4 temper and a total elongation of greater than or equal to 30 % in the T4 temper.
  • the alloys exhibit a uniform elongation of greater than or equal to 22 % and a total elongation of greater than or equal to 35 %.
  • the alloys can exhibit a uniform elongation of 20 % or more, 21 % or more, 22 % or more, 23 % or more, 24 % or more, 25 % or more, 26 % or more, 27 % or more, or 28 % or more.
  • the alloys can exhibit a total elongation of 30 % or more, 31 % or more, 32 % or more, 33 % or more, 34 % or more, 35 % or more, 36 % or more, 37 % or more, 38 % or more, 39 % or more, or 40 % or more.
  • the aluminum alloy exhibits a suitable resistance to IGC, as measured by ISO 11846B.
  • the pitting in the aluminum alloys can be completely suppressed or improved, such that the average intergranular corrosion pit depth of an alloy in the T6 temper is less than 100 ⁇ m.
  • the average intergranular corrosion pit depth can be less than 90 ⁇ m, less than 80 ⁇ m, less than 70 ⁇ m, less than 60 ⁇ m, less than 50 ⁇ m, or less than 40 ⁇ m.
  • the disclosed alloy composition is a product of a disclosed method.
  • aluminum alloy properties are partially determined by the formation of microstructures during the alloy's preparation.
  • the method of preparation for an alloy composition may influence or even determine whether the alloy will have properties adequate for a desired application.
  • the alloy described herein can be cast using a casting method.
  • the aluminum alloy as described herein can be cast from molten aluminum alloy that includes scrap alloys (e.g., from an AA6xxx series aluminum alloy scrap, an AA7xxx series aluminum alloy scrap, or a combination of these).
  • the casting process can include a Direct Chill (DC) casting process.
  • the ingot can be scalped before downstream processing.
  • the casting process can include a continuous casting (CC) process.
  • the cast aluminum alloy can then be subjected to further processing steps.
  • the processing methods as described herein can include the steps of homogenizing, hot rolling, solution heat treating, and quenching.
  • the processing methods can also include a pre-aging step and/or an artificial aging step.
  • the homogenization step can include heating the ingot prepared from an alloy composition described herein to attain a peak metal temperature (PMT) of about, or at least about, 500 °C (e.g., at least 520 °C, at least 530 °C, at least 540 °C, at least 550 °C, at least 560 °C, at least 570 °C, or at least 580 °C).
  • PMT peak metal temperature
  • the ingot can be heated to a temperature of from 500 °C to 600 °C, from 520 °C to 580 °C, from 530 °C to 575 °C, from 535 °C to 570 °C, from 540 °C to 565 °C, from 545 °C to 560 °C, from 530 °C to 560 °C, or from 550 °C to 580 °C.
  • the heating rate to the PMT can be 70 °C/hour or less, 60 °C/hour or less, 50 °C/hour or less, 40 °C/hour or less, 30 °C/hour or less, 25 °C/hour or less, 20 °C/hour or less, or 15 °C/hour or less.
  • the heating rate to the PMT can be from 10 °C/min to 100 °C/min (e.g., 10 °C/min to 90 °C/min, 10 °C/min to 70 °C/min, 10 °C/min to 60 °C/min, from 20 °C/min to 90 °C/min, from 30 °C/min to 80 °C/min, from 40 °C/min to 70 °C/min, or from 50 °C/min to 60 °C/min).
  • 10 °C/min to 90 °C/min e.g., 10 °C/min to 90 °C/min, 10 °C/min to 70 °C/min, 10 °C/min to 60 °C/min, from 20 °C/min to 90 °C/min, from 30 °C/min to 80 °C/min, from 40 °C/min to 70 °C/min, or from 50 °C/min to 60 °C/
  • the ingot is then allowed to soak (i.e., held at the indicated temperature) for a period of time.
  • the ingot is allowed to soak for up to 6 hours (e.g., from 30 minutes to 6 hours, inclusively).
  • the ingot can be soaked at a temperature of at least 500 °C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, or 6 hours, or anywhere in between.
  • a hot rolling step can be performed to form a hot band.
  • the ingots are laid down and hot-rolled with an exit temperature ranging from 230 °C to 300 °C (e.g., from 250 °C to 300 °C).
  • the hot roll exit temperature can be 230 °C, 235 °C, 240 °C, 245 °C, 250 °C, 255 °C, 260 °C, 265 °C, 270 °C, 275 °C, 280 °C, 285 °C, 290 °C, 295 °C, or 300 °C.
  • the ingot can be hot rolled to an 4 mm to 15 mm thick gauge (e.g., from 5 mm to 12 mm thick gauge).
  • the ingot can be hot rolled to an 4 mm thick gauge, 5 mm thick gauge, 6 mm thick gauge, 7 mm thick gauge, 8 mm thick gauge, 9 mm thick gauge, 10 mm thick gauge, 11 mm thick gauge, 12 mm thick gauge, 13 mm thick gauge, 14 mm thick gauge, or 15 mm thick gauge.
  • the ingot can be hot rolled to a gauge greater than 15 mm thick (e.g., a plate gauge).
  • the ingot can be hot rolled to a gauge less than 4 mm (e.g., a sheet gauge).
  • the hot band can be cooled by air and then solutionized in a solution heat treatment step.
  • the solution heat treating can include heating the final gauge aluminum alloy from room temperature to a temperature of from 520 °C to 590 °C (e.g., from 520 °C to 580 °C, from 530 °C to 570 °C, from 545 °C to 575 °C, from 550 °C to 570 °C, from 555 °C to 565 °C, from 540 °C to 560 °C, from 560 °C to 580 °C, or from 550 °C to 575 °C).
  • the final gauge aluminum alloy can soak at the temperature for a period of time.
  • the final gauge aluminum alloy is allowed to soak for up to approximately 2 hours (e.g., from 10 seconds to 120 minutes, inclusively).
  • the final gauge aluminum alloy can be soaked at the temperature of from 525 °C to 590 °C for 20 seconds, 25 seconds, 30 seconds, 35 seconds, 40 seconds, 45 seconds, 50 seconds, 55 seconds, 60 seconds, 65 seconds, 70 seconds, 75 seconds, 80 seconds, 85 seconds, 90 seconds, 95 seconds, 100 seconds, 105 seconds, 110 seconds, 115 seconds, 120 seconds, 125 seconds, 130 seconds, 135 seconds, 140 seconds, 145 seconds, 150 seconds, 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes, 40 minutes, 45 minutes, 50 minutes, 55 minutes, 60 minutes, 65 minutes, 70 minutes, 75 minutes, 80 minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, 105 minutes, 110 minutes, 115 minutes, or 120 minutes, or anywhere in between.
  • the final gauge aluminum alloy can then be cooled to a temperature of 35 °C at a quench speed that can vary between 50 °C/s to 400 °C/s in a quenching step that is based on the selected gauge.
  • the quench rate can be from 50 °C/s to 375 °C/s, from 60 °C/s to 375 °C/s, from 70 °C/s to 350 °C/s, from 80 °C/s to 325 °C/s, from 90 °C/s to 300 °C/s, from 100 °C/s to 275 °C/s, from 125 °C/s to 250 °C/s, from 150 °C/s to 225 °C/s, or from 175 °C/s to 200 °C/s.
  • the final gauge aluminum alloy is rapidly quenched with a liquid (e.g., water) and/or gas or another selected quench medium.
  • a liquid e.g., water
  • gas or another selected quench medium e.g., water
  • the final gauge aluminum alloy can be rapidly quenched with water.
  • a pre-aging step can be performed.
  • the pre-aging step can include heating the final gauge aluminum alloy after the quenching step to a temperature of from 100 °C to 160 °C (e.g., from 105 °C to 155 °C, 110 °C to 150 °C, 115 °C to 145 °C, 120 °C to 140 °C, or 125 °C to 135 °C).
  • the aluminum alloy sheet, plate, or shate is allowed to soak for up to approximately three hours (e.g., for up to 10 minutes, for up to 20 minutes, for up to 30 minutes, for up to 40 minutes, for up to 45 minutes, for up to 60 minutes, for up to 90 minutes, for up to two hours, or for up to three hours).
  • the final gauge aluminum alloy can be naturally aged or artificially aged. In some examples, the final gauge aluminum alloy can be naturally aged for a period of time to result in the T4 temper. In certain aspects, the final gauge aluminum alloy in the T4 temper can be artificially aged (AA) at 180 °C to 225 °C (e.g., 185 °C, 190 °C, 195 °C, 200 °C, 205 °C, 210 °C, 215 °C, 220 °C, or 225 °C) for a period of time.
  • AA artificially aged
  • the final gauge aluminum alloy can be artificially aged for a period from 15 minutes to 8 hours (e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, or 8 hours or anywhere in between) to result in the T6 temper.
  • 15 minutes to 8 hours e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, or 8 hours or anywhere in between
  • the alloys and methods described herein can be used in automotive, electronics, and transportation applications, such as commercial vehicle, aircraft, or railway applications, or other applications.
  • the alloys could be used for chassis, cross-member, and intra-chassis components (encompassing, but not limited to, all components between the two C channels in a commercial vehicle chassis) to gain strength, serving as a full or partial replacement of high-strength steels.
  • the alloys can be used in T4 and T6 tempers.
  • the alloys and methods can be used to prepare motor vehicle body part products.
  • the disclosed alloys and methods can be used to prepare automobile body parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, side panels, floor panels, tunnels, structure panels, reinforcement panels, inner hoods, or trunk lid panels.
  • the disclosed aluminum alloys and methods can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.
  • the disclosed alloys can be used for other specialties applications, such as automotive battery plates/shates.
  • the described alloys and methods can also be used to prepare housings for electronic devices, including mobile phones and tablet computers.
  • the alloys can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones) and tablet bottom chassis, with or without anodizing.
  • the alloys can also be used to prepare other consumer electronic products and product parts.
  • Exemplary consumer electronic products include mobile phones, audio devices, video devices, cameras, laptop computers, desktop computers, tablet computers, televisions, displays, household appliances, video playback and recording devices, and the like.
  • Exemplary consumer electronic product parts include outer housings (e.g., facades) and inner pieces for the consumer electronic products.
  • Table 4A Alloy Cu Mg Mn Si Zn Fe Zr 1 0.60 0.9 - 1.2 0.19 0.9 - 1.1 ⁇ 0.01 0.16 - 0.19 0 2 0.80 1.0 0.17-0.19 1.1 1.5 - 3.0 0.18 - 0.20 0.006 3 0.6 - 0.7 2.0 - 2.25 0.07 - 0.10 1.0 2.5 - 3.0 0.14 - 0.17 0.09 - 0.10 4 0.7 - 0.8 1.5 0.14-0.15 0.55 - 0.65 1.55 0.16 - 0.18 0 5 1.0 1.5 0.14-0.15 0.63 - 0.67 2.0 - 3.0 0.17 0
  • Alloy 1 represents comparative AA6xxx series aluminum alloys exhibiting high strength due to Mg 2 Si strengthening precipitates in the aluminum alloy.
  • Alloy 2 represents comparative aluminum alloys exhibiting improved corrosion resistance and a slight decrease in strength upon adding Zn. Alloys 1 and 2, wherein the ratio of Cu/[Zn/(Mg/Si)] does not fall in the range of from 0.7 to 1.4, exhibit significant IGC and failure in a 90° bend test.
  • Alloy 3 represents exemplary aluminum alloys wherein the ratios of Cu/[Zn/(Mg/Si)] are closer to the range of from 0.7 to 1.4 than Alloy 2, exhibiting a decrease in strength with excellent formability and resistance to IGC.
  • Alloy 4 represents exemplary aluminum alloys wherein the ratios of Cu/[Zn/(Mg/Si)] fall within the range of from 0.7 to 1.4, but the ratios of Zn/(Mg/Si) do not fall within a range of from 0.75 to 1.4, exhibiting significant IGC and poor formability, and increased strength when compared to Alloy 3.
  • Alloy 5 represents exemplary aluminum alloys wherein the ratios of Mg/Si, Zn/(Mg/Si), and Cu/[Zn/(Mg/Si)] all fall within the respective ranges, exhibiting high strength, good formability, and good resistance to corrosion.
  • exemplary alloys were produced according to the direct chill casting methods described herein.
  • the alloy compositions are summarized in Table 6 below: Table 6 Alloy Si Fe Cu Mn Mg Cr Zn Ti A 0.65 0.20 1.10 0.15 1.50 0.05 2.0 0.02 B 0.65 0.20 1.10 0.15 1.50 0.05 2.5 0.02 C 0.65 0.20 1.10 0.15 1.50 0.05 3.0 0.02 All expressed in wt. %; remainder Al.
  • Exemplary alloys were produced by direct chill casting and processed according to the methods described herein.
  • the Mg and Cu content can provide precipitation of an M phase (e.g., MgZn 2 / Mg(Zn, Cu) 2 ), providing precipitates that can increase strength in the aluminum alloy.
  • Evaluation of the M phase (e.g., MgZn 2 ) precipitates was performed as a function of Mg content in the exemplary alloys.
  • Figure 1 is a graph showing an increase in Mg content from 1.0 wt. % to 3.0 wt. %.
  • a mass fraction of the M phase precipitates i) increases proportionally with increasing Mg content from 1.0 wt. % to 1.5 wt.
  • Figure 2 is a graph showing differential scanning calorimetry (DSC) analysis of samples of exemplary Alloy 3 described above (referred to as "H1," “H2,” and “H3").
  • Exothermic peak A indicates precipitate formation in the exemplary alloys and endothermic peak B indicates melting points for the exemplary Alloy 3 samples.
  • Figure 3 is a graph showing DSC analysis of samples of the exemplary Alloy 5 described above (referred to as "H5,” “H6,” and “H7").
  • Exothermic peak A indicates M phase precipitates.
  • Exothermic peak B indicates ⁇ " (Mg 2 Si) precipitates, showing formation of the strengthening precipitates during an artificial aging step and corresponding to the increase in strength of the exemplary aluminum alloys.
  • Endothermic peak C indicates melting points for the exemplary Alloy 5 samples.
  • Figure 4A is a transmission electron microscope (TEM) micrograph showing three distinct strengthening precipitate phases, M (MgZn 2 ) 410, ⁇ " (Mg 2 Si) 420, and L (Al 4 Mg 8 Si 7 Cu 2 ) 430.
  • a combination of the three precipitate phases produces a yield strength of about 370 MPa in a T6 temper for a 10 mm gauge aluminum alloy (e.g., Alloy 5).
  • Figure 4B is a TEM micrograph showing Zr-containing precipitate particles 440. Excess Zr in the exemplary alloys can cause coarse needle-like particles to form. The coarse, needle-like Zr-containing precipitate particles 440 can reduce formability of the exemplary alloys. Likewise, too little Zr in the exemplary alloys can fail to provide desired Al 3 Zr and/or (Al,Si) 3 Zr dispersoids.
  • Figure 5 is a graph showing the density of each distinct strengthening precipitate phase, M (MgZn 2 ), L (Al 4 Mg 8 Si 7 Cu 2 ), and ⁇ " (Mg 2 Si), in number of precipitate particles per square millimeter (#/mm 2 ) and as a fraction of analyzed area each distinct precipitate phase occupies (%) for Alloy C (see Table 6).
  • the ⁇ " precipitates are predominant in both density and occupied area due to their shape.
  • the smaller M and L precipitates occupy less area accordingly, and are present in densities comparable to the ⁇ " precipitates.
  • Figure 6 shows optical micrographs of samples of Alloy 3 as described above. Precipitates were analyzed in as-cast samples (top row), homogenized samples (center row), and hot rolled samples reduced to a 10 mm gauge (bottom row). Eutectic phase precipitates are evident in the as-cast samples. Precipitates did not fully dissolve after homogenization, as shown in the center row of micrographs. Coarse (e.g., greater than about 5 microns) precipitates are evident in the hot rolled samples.
  • Figure 7 shows optical micrographs of samples of Alloy 3 described above after casting, homogenization, hot rolling to a 10 mm gauge and various solution heat treatment procedures to achieve maximum dissolution of strengthening precipitates during solution heat treatment.
  • panel A shows an Alloy 3 sample solutionized at a temperature of 555 °C for 45 minutes.
  • panel B shows an Alloy 3 sample solutionized at a temperature of 350 °C for 45 minutes, then at a temperature of 500 °C for 30 minutes, and finally at a temperature of 565 °C for 30 minutes.
  • FIG. 7 panel C shows an Alloy 3 sample solutionized at a temperature of 350 °C for 45 minutes, then at a temperature of 500 °C for 30 minutes and finally a temperature of 565 °C for 60 minutes.
  • panel D shows an Alloy 3 sample solutionized at a temperature of 560 °C for 120 minutes.
  • panel E shows an Alloy 3 sample solutionized at a temperature of 500 °C for 30 minutes, then at a temperature of 570 °C for 30 minutes.
  • panel F shows an Alloy 3 sample solutionized at a temperature of 500 °C for 30 minutes, then at a temperature of 570 °C for 60 minutes.
  • Figure 8 shows optical micrographs of samples of Alloy 5 as described above. Precipitates were analyzed in as-cast samples (top row) and homogenized samples (bottom row). Eutectic phase precipitates are evident in the as-cast samples. The precipitates did not fully dissolve after homogenization, as seen in the bottom row of micrographs. Alloy 5, however, exhibited fewer undissolved precipitates as compared to Alloy 3 after homogenization, due to changes in solute levels (e.g., the Mg levels, Si levels, and the Mg/Si ratio).
  • solute levels e.g., the Mg levels, Si levels, and the Mg/Si ratio
  • Figure 9 shows optical micrographs of samples of Alloy 5 described above after hot rolling to a 10 mm gauge.
  • panels A, B, and C show precipitate particles (seen as dark spots) in the exemplary alloy samples after hot rolling to a 10 mm gauge.
  • Figure 9 , panels D, E, and F show grain structure after hot rolling the exemplary Alloy 5 samples to a gauge of 10 mm. Grains were not fully recrystallized due to a low hot rolling exit temperature of about 280 °C to about 300 °C.
  • Figure 10 shows optical micrographs of samples of Alloy 5 described above after hot rolling to a 10 mm gauge, solution heat treating, and natural aging to a T4 temper.
  • Figure 10 , panels A, B, and C show very few precipitate particles in the exemplary alloy samples in T4 temper.
  • Figure 10 , panels D, E, and F show a fully recrystallized grain structure of the exemplary Alloy 5 samples in T4 temper.
  • Figure 11 is a graph showing the electrical conductivities of samples of Alloy 3 after casting, homogenization, hot rolling, various solution heat treatment procedures, and artificial aging (AA).
  • the electrical conductivity data i.e., conductivity as a percent of the International Annealed Copper Standard (%IACS)
  • %IACS International Annealed Copper Standard
  • Figure 12 is a graph showing the electrical conductivities of samples of Alloy 5 (referred to as "HR5,” “HR6,” and “HR7”) after casting, homogenization, hot rolling, solution heat treating, and artificial aging.
  • the electrochemical testing data shows large amounts of precipitation after hot rolling.
  • solution heat treatment procedures were evaluated in an attempt to dissolve the precipitates.
  • Solution heat treating was effective in dissolving precipitates.
  • artificial aging provided strengthening precipitate formation providing optimal strength.
  • Figure 13 is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for the exemplary Alloys A, B, and C described above.
  • the alloys were solutionized at a temperature of 565 °C for 45 minutes, pre-aged at a temperature of 125 °C for 2 hours, and artificially aged at a temperature of 200 °C for 4 hours to result in a T6 temper.
  • Each alloy exhibited a yield strength greater than 370 MPa, an ultimate tensile strength greater than 425 MPa, a uniform elongation greater than 10 %, and a total elongation greater than 17 %.
  • Increased Zn content did not significantly affect the strength of the exemplary aluminum alloys, but did improve resistance to intergranular corrosion and formability.
  • Figure 14A is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 3 in T4 temper (referred to as "H1 T4,” “H2 T4,” and “H3 T4").
  • Figure 14B is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 3 in T6 temper (referred to as "H1 T6,” “H2 T6,” and “H3 T6").
  • Figure 15 is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 3 in T6 temper (referred to as "H1," "H2,” and “H3”) after various aging procedures, as indicated in the x-axis of the graph.
  • H1, "H2,” and "H3”
  • H1 total elongation
  • Figure 16A is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 4 in T4 temper (referred to as "HR1,” “HR2,” “HR3,” and “HR4").
  • Figure 16B is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 4 in T6 temper after various aging procedures (referred to as "HR1,” “HR2,” “HR3,” and “HR4").
  • HR1," "HR2,” “HR3,” and “HR4 a maximum strength of 360 MPa was achieved.
  • aging at low temperatures e.g., less than 250 °C
  • Figure 17A is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 5 in T4 temper after casting, homogenization, hot rolling to a gauge of 10 mm, solution heat treating, and various quenching techniques (referred to as “HR5,” “HR6,” and “HR7”). Air cooled samples are referred to as “AC” and water quenched samples are referred to as "WQ" after hot rolling.
  • Figure 17B is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 5 in T6 temper after casting, homogenization, hot rolling to a gauge of 10 mm, solution heat treating, various quenching techniques, and various aging procedures (referred to as "HR5,” “HR6,” and “HR7”). Air cooled samples are referred to as “AC” and water quenched samples are referred to as "WQ" after hot rolling.
  • Artificial aging to a T6 temper provided high-strength aluminum alloys having yield strengths of about 360 MPa to about 370 MPa.
  • Figure 18A is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 5 in T4 temper (referred to as "HR5,” “HR6,” and “HR7”) after casting, homogenization, hot rolling to a gauge of 10 mm, and solution heat treating.
  • Figure 18B is a graph showing yield strength (left histogram in each set), ultimate tensile strength (right histogram in each set), uniform elongation (open circle), and total elongation (open diamond) for samples of the exemplary Alloy 5 in T6 temper (referred to as "HR5,” “HR6,” and “HR7”) after casting, homogenization, hot rolling to a gauge of 10 mm, solution heat treating, and various aging procedures, as indicated in the graph.
  • Artificial aging to a T6 temper provided high-strength aluminum alloys having yield strengths of about 360 MPa to about 370 MPa.
  • Figure 19 is a graph showing load displacement data for a 90 ° bend test formability of samples of the exemplary Alloy 5 as described above (referred to as "HR5,” “HR6,” and “HR7”). Samples tested in a direction longitudinal to a rolling direction are indicated by “-L,” and sample tested in a transverse direction to the rolling direction are indicated by “-T.” Alloy 5 was subjected to casting, homogenization, hot rolling to a gauge of 10 mm, solution heat treating, and natural aging for one week to provide Alloy 5 samples in T4 temper. Samples were subjected to a 90° bend test and load displacement (left axis) and maximum load (right axis) were recorded.
  • Figure 20 is a graph showing load displacement data for a 90 ° bend test formability of samples of the exemplary Alloy 5 as described above (referred to as "HR5,” “HR6,” and “HR7”). Samples tested in a direction longitudinal to a rolling direction are indicated by “-L,” and sample tested in a transverse direction to the rolling direction are indicated by “-T.” Alloy 5 was subjected to casting, homogenization, hot rolling to a gauge of 10 mm, solution heat treating, pre-aging at a temperature of 125 °C for 2 hours (referred to as "PX”) and natural aging for one week to provide Alloy 5 samples in T4 temper. Samples were subjected to a 90° bend test and load displacement (left axis) and maximum load (right axis) were recorded.
  • Figure 21 is a graph showing load displacement data for a 90 ° bend test formability of samples of the exemplary Alloy 5 as described above.
  • the sample tested in a direction longitudinal to a rolling direction is indicated by "-L” and the sample tested in a transverse direction to the rolling direction is indicated by "-T.”
  • the samples were subjected to casting, homogenization, hot rolling to a gauge of 10 mm, solution heat treating, pre-aging at a temperature of 125 °C for 2 hours and natural aging for one month to provide Alloy 5 samples in T4 temper.
  • the samples were subjected to a 90° bend test and load displacement (left axis) and maximum load (right axis) were recorded. There was no noticeable change in formability from one week of natural aging to one month of natural aging with pre-aging employed during production.
  • Figure 22 shows optical micrographs showing the effects of corrosion testing on alloys described above.
  • the alloys were subjected to corrosion testing according to ISO standard 11846B (e.g., 24 hour immersion in a solution containing 3.0 wt. % sodium chloride (NaCl) and 1.0 volume % hydrochloric acid (HCl) in water).
  • Figure 22 , panel A, and Figure 22 , panel B show effects of corrosion testing in comparative Alloy 2 described above.
  • Corrosion morphology is an intergranular corrosion (IGC) attack.
  • Figure 22 , panels C, D, and E show the effects of corrosion testing in exemplary Alloy 3 as described above.
  • Corrosion morphology is a pitting attack.
  • a pitting attack is a more desirable corrosion morphology causing less damage to the alloy and indicating corrosion resistance in the exemplary alloys.
  • Figure 23 shows optical micrographs showing the effects of corrosion testing on samples of exemplary Alloy 4 as described above.
  • Evident in the micrographs is significant IGC attack due to the composition of Alloy 4, wherein the ratio of Cu/[Zn/(Mg/Si)] is within the range of from 0.7 to 1.4, but the ratio of Zn/(Mg/Si) is not within the range of from 0.75 to 1.4, resulting in significant IGC attack.
  • Figures 24A, 24B, and 24C are optical micrographs showing the results of corrosion testing on the exemplary alloys described above.
  • Figure 24A shows intergranular corrosion (IGC) attack in Alloy A.
  • Figure 24B shows intergranular corrosion attack in Alloy B.
  • Figure 24C shows intergranular corrosion attack in Alloy C.
  • increasing Zn content changes corrosion morphology from IGC to pitting, and corrosion attack depth is decreased from about 150 ⁇ m (Alloy A, Figure 24A ) to less than 100 ⁇ m (Alloy C, Figure 24C ).

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Claims (16)

  1. Alliage d'aluminium comprenant 0,25 à 1,3 % en poids de Si, 1,0 à 2,5 % en poids de Mg, 0,5 à 1,5 % en poids de Cu, jusqu'à 0,2 % en poids de Fe, jusqu'à 3,0 % en poids de Zn, jusqu'à 0,15 % en poids de Zr, jusqu'à 0,5 % en poids de Mn, jusqu'à 0,15 % en poids d'impuretés, le reste sous forme de Al, dans lequel un rapport de Mg à Si (rapport Mg/Si) est de 1,5 à 1 à 3,5 à 1.
  2. Alliage d'aluminium selon la revendication 1, comprenant 0,55 à 1,1 % en poids de Si, 1,25 à 2,25 % en poids de Mg, 0,6 à 1,0 % en poids de Cu, 0,05 à 0,17 % en poids de Fe, 1,5 à 3,0 % en poids de Zn, jusqu'à 0,15 % en poids d'impuretés, le reste sous forme de Al.
  3. Alliage d'aluminium selon la revendication 1 ou 2, comprenant 0,65 à 1,0 % en poids de Si, 1,5 à 2,25 % en poids de Mg, 0,6 à 1,0 % en poids de Cu, 0,12 à 0,17 % en poids de Fe, 2,0 à 3,0 % en poids de Zn, jusqu'à 0,15 % en poids d'impuretés, le reste sous forme de Al.
  4. Alliage d'aluminium selon l'une quelconque des revendications 1 à 3, comprenant Zr et en particulier, dans lequel Zr est présent en une quantité de 0,09 à 0,12 % en poids.
  5. Alliage d'aluminium selon l'une quelconque des revendications 1 à 4, comprenant Mn et en particulier, dans lequel Mn est présent en une quantité de 0,05 à 0,3 % en poids.
  6. Alliage d'aluminium selon l'une quelconque des revendications 1 à 5, dans lequel le rapport Mg/Si est de 2,0 à 1 à 3,0 à 1.
  7. Alliage d'aluminium selon la revendication 6, dans lequel un rapport de Zn au rapport Mg/Si (rapport Zn/(Mg/Si)) est de 0,75 à 1 à 1,4 à 1 et en particulier, dans lequel le rapport Zn/(Mg/Si) est de 0,8 à 1 à 1,1 à 1.
  8. Alliage d'aluminium selon la revendication 7, dans lequel un rapport de Cu au rapport Zn/(Mg/Si) (rapport Cu/[Zn/(Mg/Si)]) est de 0,7 à 1 à 1,4 à 1 et en particulier, dans lequel le rapport Cu/[Zn/(Mg/Si)] est de 0,8 à 1 à 1,1 à 1.
  9. Produit en alliage d'aluminium, comprenant l'alliage d'aluminium selon l'une quelconque des revendications 1 à 8.
  10. Produit en alliage d'aluminium selon la revendication 9, dans lequel le produit en alliage d'aluminium comprend une limite d'élasticité d'au moins 340 MPa à l'état T6 et en particulier, dans lequel la limite d'élasticité est de 360 MPa à 380 MPa à l'état T6 et/ou dans lequel le produit en alliage d'aluminium comprend une profondeur moyenne de piqûres de corrosion intergranulaire inférieure à 100 µm à l'état T6 et/ou dans lequel le produit en alliage d'aluminium comprend un rapport r/t (aptitude au pliage) de 0,5 ou moins à l'état T4.
  11. Produit en alliage d'aluminium selon l'une quelconque des revendications 9 ou 10, dans lequel le produit en alliage d'aluminium comprend un ou plusieurs précipités choisis dans le groupe consistant en MgZn2/Mg(Zn,Cu)2, Mg2Si et Al4Mg8Si7Cu2.
  12. Produit en alliage d'aluminium selon la revendication 11, dans lequel le produit en alliage d'aluminium comprend MgZn2/Mg(Zn,Cu)2 en une quantité moyenne d'au moins 300 000 000 particules par mm2 et/ou dans lequel le produit en alliage d'aluminium comprend Mg2Si en une quantité moyenne d'au moins 600 000 000 particules par mm2 et/ou dans lequel le produit en alliage d'aluminium comprend Al4Mg8Si7Cu2 en une quantité moyenne d'au moins 600 000 000 particules par mm2.
  13. Produit en alliage d'aluminium selon l'une quelconque des revendications 11 ou 12, dans lequel le produit en alliage d'aluminium comprend MgZn2/Mg(Zn,Cu)2, Mg2Si et Al4Mg8Si7Cu2.
  14. Produit en alliage d'aluminium selon la revendication 13, dans lequel un rapport de Mg2Si à Al4Mg8Si7Cu2 est de 1:1 à 1,5:1 et/ou dans lequel un rapport de Mg2Si à MgZn2/Mg(Zn,Cu)2 est de 1,5:1 à 3:1 et/ou dans lequel un rapport de Al4Mg8Si7Cu2 à MgZn2/Mg(Zn,Cu)2 est de 1,5:1 à 3:1.
  15. Procédé de production d'un alliage d'aluminium, comprenant:
    la coulée d'un alliage d'aluminium selon l'une quelconque des revendications 1 à 8 pour former un produit coulé en alliage d'aluminium;
    l'homogénéisation du produit coulé en alliage d'aluminium;
    le laminage à chaud pour fournir un alliage d'aluminium de calibre final; et
    le traitement thermique de mise en solution de l'alliage d'aluminium de calibre final.
  16. Procédé selon la revendication 15, comprenant en outre le pré-vieillissement de l'alliage d'aluminium de calibre final et/ou dans lequel l'alliage d'aluminium est coulé à partir d'un alliage d'aluminium fondu comprenant de la ferraille et en particulier, dans lequel la ferraille comprend un alliage d'aluminium de la série 6xxx, un alliage d'aluminium de la série 7xxx, ou une combinaison de ceux-ci.
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CN120290945A (zh) * 2025-06-10 2025-07-11 永臻科技(芜湖)有限公司 一种光伏边框用高强耐蚀易加工铝合金型材及其制备方法

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US5571347A (en) 1994-04-07 1996-11-05 Northwest Aluminum Company High strength MG-SI type aluminum alloy
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JP5160930B2 (ja) * 2008-03-25 2013-03-13 株式会社神戸製鋼所 曲げ圧壊性と耐食性に優れたアルミニウム合金押出材およびその製造方法
CN101805862B (zh) 2010-03-29 2011-06-01 江苏大学 锆微合金化的6013型铝合金及其制备方法
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CN110892086A (zh) 2020-03-17
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WO2019013744A1 (fr) 2019-01-17
BR112020000305A2 (pt) 2020-07-14
KR20200028411A (ko) 2020-03-16
EP3652356A1 (fr) 2020-05-20
CA3069499A1 (fr) 2019-01-17
JP2020527648A (ja) 2020-09-10
JP7191077B2 (ja) 2022-12-16
ES2933801T3 (es) 2023-02-14

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