US20220348401A1

US20220348401A1 - Aluminum flat rolled products with high recycled content for light gauge packaging solutions and related methods

Info

Publication number: US20220348401A1
Application number: US17/640,745
Authority: US
Inventors: Martin Frank; Michael Knechtel; Martin Bottenheft; Patrick Lenzen; Serge Gaudin; Nicolas C. Kamp; Kevin Mark Johnson; Patrick NEUMANN; Andy Doran
Original assignee: Novelis Inc Canada
Current assignee: Novelis Inc Canada
Priority date: 2019-10-02
Filing date: 2020-10-02
Publication date: 2022-11-03
Also published as: CA3151478A1; EP4037996A1; AU2024202433A1; AU2020358832A1; WO2021067695A1; CA3234627A1; CA3151478C; BR112022002842A2; CN114466799A; MX2022003928A; JP2022550180A; JP2024026261A; KR20220050197A

Abstract

Described herein are aluminum alloy products for packaging and/or producing a beverage. The aluminum alloy products include beverage capsules. The aluminum alloy products can include a 3xxx series aluminum alloy. The aluminum alloy products can include at least 50 wt. % recycled aluminum. Also described herein are methods for processing the aluminum alloys to produce beverage capsules and other packaging products.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/909,291, filed Oct. 2, 2019, which is incorporated herein by reference in its entirety.

FIELD

The present disclosure is directed to aluminum alloy products and the properties of such aluminum alloy products. The disclosure further relates to aluminum beverage products with high recycled content and methods of producing and processing the same.

BACKGROUND

Beverage capsules are well known and widely used. Aluminum can provide good rigidity, formability, and gas and light barrier characteristics for food packaging. Aluminum foils used for capsule packaging include a soft annealed AA8011A alloy. Incumbent alloys for capsules have low recycled content. Elements found in recycled aluminum such as Mg or Mn, and elements that may accumulate through recycling, such as Fe, can negatively influence properties such as fracture behavior or earing. Utilizing recycled aluminum is environmentally friendly. Creating new metal from recycled aluminum only requires 5% of the energy needed to produce the primary aluminum used in aluminum alloys. Reducing the amount of packaging material by reducing the thickness of the material can positively impact the environment. However, reducing the thickness of packaging material can compromise the balance between formability and mechanical resistance of the packaging material and limit these efforts. 3xxx series aluminum alloys are a common packaging material for beverage cans, including 3004/3104 in H19 temper. However, the properties of the 3xxx series aluminum alloys used in beverage cans with a typical gauge of 0.23-0.35 mm, tensile strength of about 260 MPa, and elongation at break of about 4%, are in a different operating window compared to the properties of the aluminum alloy materials used for beverage capsules.

SUMMARY

Covered embodiments of the invention are defined by the claims, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings, and each claim.
Described herein are aluminum alloy capsules. In some embodiments, an aluminum alloy capsule comprises a dome-shaped body comprising a lip, where the lip extends outwardly from the body, and a cover secured with the lip. The body defines a cavity configured to contain a substance for preparation of a beverage. The cover can form a seal around the lip of the body to seal the substance within the body. In some embodiments, at least one of the body and the cover comprises a 3xxx series aluminum alloy. In some embodiments, the 3xxx series aluminum alloy comprises AA3104.
The aluminum alloy capsules described herein can provide an improvement over conventional aluminum alloy capsules with the use of more recycled content in the aluminum alloy and enabling future downgauging steps through a new balance of formability and strength properties. In certain embodiments, the 3xxx series aluminum alloy comprises at least 50 wt. % recycled aluminum. Optionally, the 3xxx series aluminum alloy can comprise at least 80 wt. % recycled aluminum. In some cases, the recycled aluminum includes at least one of process run-around scrap, post-manufacturing scrap, or post-consumer scrap aluminum.
In some cases, the 3xxx series aluminum alloy may be processed to produce an O temper alloy. In some embodiments, the aluminum alloy capsule comprises a thickness of about 30 μm to about 170 μm (e.g., from about 50 μm to less than about 150 μm or from about 75 μm to about 120 μm). Optionally, the aluminum alloy capsule can comprise a thickness of about 70 μm to about 120 μm (e.g., from about 70 μm to less than about 110 μm or from about 80 μm to about 100 μm).
Further described herein are methods of producing an aluminum alloy product with recycled content, such as an aluminum beverage capsule. The method comprises melting recycled aluminum into liquid metal, adding an alloying element to the liquid metal to form a modified liquid metal, casting the modified liquid metal to form a cast aluminum alloy, heating the cast aluminum alloy, hot rolling the cast aluminum alloy to produce a rolled product comprising a thickness of 1.5 mm to 10 mm, and cold rolling the rolled product to produce an aluminum alloy product. In some examples, the alloying element comprises manganese. In some examples, the alloying element comprises magnesium. Optionally, the alloying element may comprise manganese and magnesium. Optionally, the alloying element may further comprise silicon. In certain examples, heating the cast aluminum alloy can comprise homogenizing the cast aluminum alloy. Optionally, the method may further comprise annealing the aluminum alloy product to produce an O temper product. In some examples, the method may further comprise cleaning the aluminum alloy product with a mild alkaline or acidic agent. In some examples, the modified liquid metal can comprise at least 50 wt. % recycled aluminum (e.g., at least about 60 wt. % of the recycled aluminum or at least about 75 wt. % of the recycled aluminum). Optionally, the modified liquid metal may include at least 80 wt. % recycled aluminum (e.g., at least about 85 wt. % of the recycled aluminum or at least about 90 wt. % of the recycled aluminum). The recycled aluminum may comprise process run-around scrap, post-manufacturing scrap, and/or post-consumer scrap aluminum.
Also described herein is an aluminum alloy product prepared according to the method described herein. The aluminum alloy can comprise a 3xxx series aluminum alloy. The aluminum alloy product can be a sheet. The aluminum alloy product can be used for packaging. In some examples, the aluminum alloy product is a package for preparing a beverage. In certain examples, the aluminum alloy product is a beverage capsule.
Achieving a level of strength and elongation while achieving the earing property for capsule packaging can be a challenge. The aluminum alloys described herein may exhibit good earing and mechanical properties, even when down-gauged. The aluminum alloy products may exhibit less than 2.0% earing in O temper. In certain examples, the aluminum alloy products exhibit less than 1.5% earing in O temper. The aluminum alloy products can comprise a thickness of from about 30 μm to about 170 μm (e.g., from about 50 μm to less than about 150 μm or from about 80 μm to about 140 μm). In some cases, the aluminum alloy products comprise a thickness of from about 70 μm to about 120 μm (e.g., from about 75 μm to less than about 115 μm or from about 90 μm to about 110 μm). The aluminum alloy products can have an ultimate tensile strength of from about 165 MPa to about 190 MPa (e.g., from about 170 MPa to less than about 185 MPa or from about 175 MPa to about 180 MPa) when the aluminum alloy products are in O temper. In some examples, the aluminum alloy products have a yield strength at 0.2% strain of from 70 MPa to 90 MPa (e.g., from about 75 MPa to less than about 90 MPa or from about 80 MPa to about 85 MPa) when the aluminum alloy products are in O temper. The aluminum alloy products may have a total elongation of at least 10% when the aluminum alloy products are in O temper, using A100 testing geometry.
Other objects and advantages of the invention will be apparent from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF DRAWINGS

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.

FIGS. 1A and 1B are a side view and a perspective view, respectively, of a beverage capsule according to one example of the present disclosure.

FIGS. 2A and 2B are perspective views of a beverage capsule according to one example of the present disclosure.

FIG. 3 is an exploded view of a beverage capsule according to one example of the present disclosure.

DETAILED DESCRIPTION

Described herein are aluminum alloy products, such as aluminum alloy capsules, aluminum alloy products with high recycled content, and methods for making the products. The aluminum alloy products and methods described herein provide improved aluminum alloy products with reduced raw material usage. For example, the aluminum alloy products described herein can include recycled aluminum (e.g., at least 50 wt. % or at least 80 wt. % recycled aluminum) as compared to conventional aluminum alloy products used for aluminum alloy capsules. The aluminum alloy products described herein have superior strength properties compared with capsules and other packaging products made from a conventional 8xxx series aluminum alloy.
In some examples, an aluminum alloy capsule may comprise a dome-shaped body and a cover. The body defines a cavity configured to contain a substance for preparation of a beverage. The capsule can comprise a 3xxx series aluminum alloy. Optionally, the 3xxx series aluminum alloy may include at least 50 wt. % recycled aluminum.

Definitions and Descriptions

The terms “invention,” “the invention,” “this invention,” and “the present invention” used herein are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “3xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.
As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.
As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 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.
As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.3 mm, or less than about 0.1 mm.
As used herein, the term foil indicates an alloy thickness in a range of up to about 0.2 mm (i.e., 200 microns (μm)). For example, a foil may have a thickness of up to 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 110 μm, 120 μm, 130 μm, 140 μm, 150 μm, 160 μm, 170 μm, 180 μm, 190 μm, or 200 μm.
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.
As used herein, the term metal product can refer to any suitable shape or size of cast product, as appropriate.
Reference is 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 O 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).
All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.
The following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %) based on the total weight of the alloy. In certain examples of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15% for the sum of the impurities.
As used herein, the terms recycled scrap (e.g., recycled stock) can refer to a collection of recycled metal. Recycled scrap can include materials recycled from any suitable source, such as from a metal production facility (e.g., metal casting facility), from a metalworking facility (e.g., production facility that uses metal product to create consumable products), from post-consumer sources (e.g., regional recycling facilities), or from other sources. Certain aspects of the present disclosure can be well-suited for recycled scrap from sources other than a metal production facility, since such recycled scrap likely contains a mixture of alloys or is mixed with other impurities or elements (e.g., such as paints or coatings). Recycled scrap can refer to recycled aluminum, such as recycled sheet aluminum products (e.g., aluminum pots and pans), recycled cast aluminum products (e.g., aluminum grills and wheel rims), UBC scrap (e.g., used beverage cans), aluminum wire, and other aluminum materials.
As used herein, the term earing in relation to measurements refers to the mean earing of cup heights:
$Mean earing (%) = \frac{average peak height - average valley height}{cup height}$

Aluminum Alloys and Products

Described herein are aluminum alloy products and methods of preparing the aluminum alloy products. Products described herein include, for example, aluminum alloy capsules. Such products can be used, for example, as beverage capsules.
In some examples, an aluminum alloy capsule comprises a dome-shaped body comprising a lip. The lip extends outwardly from the body. The body defines a cavity configured to contain a substance for preparation of a beverage. The capsule can further comprise a cover secured with the lip. The cover can form a seal around the lip of the body to seal the substance within the body. The substance housed within the capsule for preparation of a beverage may include coffee, tea, cocoa, concentrates for dairy-based beverages, lemonade, cider, and fruit-based drinks, among others.
In some examples, the body can comprise a 3xxx series aluminum alloy. In some examples, the cover can also comprise a 3xxx series aluminum alloy. Optionally, the body and cover can comprise a 3xxx series aluminum alloy. The 3xxx series aluminum alloy for the body and the cover may be the same or different type of alloy.
Aluminum alloys for use in the products and methods described herein include 3xxx series aluminum alloys. Suitable 3xxx series aluminum alloys include, for example, AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065.
In some examples, the aluminum alloy products described herein include manganese (Mn) in an amount of from about 0.1% to about 2.0% (e.g., from about 0.1% to about 1.5% or from about 0.5% to about 1.5%) based on the total weight of the alloy. For example, the aluminum alloy products can include 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 033%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.6%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.7%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.8%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.9%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, or 2.0% Mn. All are expressed in wt. %.
In some examples, the aluminum alloy products described herein include magnesium (Mg) in an amount of from about 0.1% to about 2.0% (e.g., from about 0.1% to about 1.5% or from about 0.5% to about 1.5%) based on the total weight of the alloy. For example, the aluminum alloy products can include 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 033%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.6%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.7%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.8%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.9%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98% Mg. All are expressed in wt. %.
In some examples, the aluminum alloy products described herein include silicon (Si) in an amount up to about 1.5 wt. % (e.g., from about 0.01% to about 1.50%, from about 0.20% to about 1.0%, or from about 0.3% to about 0.9%) based on the total weight of the alloy. For example, the aluminum alloy products can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 033%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, or 1.50% Si. In some cases, Si is not present in the alloy (i.e., 0%). All are expressed in wt. %.
Optionally, the aluminum alloy products described herein can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01% or below. These impurities may include, but are not limited to, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Accordingly, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be present in alloys (in total) in amounts of 0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below or 0.01% or below. In some cases, the sum of all impurities does not exceed 0.15% (e.g., 0.10%). All are expressed in wt. %. The remaining percentage of the alloy may be aluminum.
Optionally, the aluminum alloy products described herein include recycled scrap in an amount at or more than about 50 wt. % (e.g., more than about 60%, more than about 70%, or more than about 80%) based on the total weight of the alloy. For example, the aluminum alloy products may include 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99%. All are expressed in wt. %.
In some cases, the recycled scrap includes recycled aluminum scrap, such as used beverage can (UBC) scrap. UBC scrap, for example, generally contains a mixture of metal from various alloys, such as metal from can bodies (e.g., AA3104, AA3004, or other 3xxx series aluminum alloy) and can ends (e.g., AA5182 or other 5xxx series aluminum alloy). Other recycled scrap includes other mixtures of alloys. Further, recycled scrap can contain other impurities and alloying elements, which end up in the liquid metal when the recycled scrap is melted. The recycled aluminum may comprise process run-around scrap, post-manufacturing scrap, and/or post-consumer scrap aluminum. Run-around scrap is generated during aluminum product manufacturing (e.g., ingot scalping and edge trimming during the production of an aluminum sheet). Post-manufacturing scrap is generated in the manufacturing process of aluminum alloy products (e.g., automotive part production waste and beverage can punch waste). Post-consumer is scrap generated after the product use by consumers is complete (e.g., used beverage cans).
Various products including the aluminum alloys described herein can be produced. The aluminum alloy products described herein can have any suitable gauge. In some examples, the aluminum alloy product can be a sheet. Optionally, the sheet gauge is less than about 240 μm (e.g., from about 170 μm to less than about 240 μm, from about 180 μm to about 230 μm, or from about 190 μm to about 220 μm). For example, the sheet can have a gauge of about 170 μm, 175 μm, 180 μm, 185 μm, 190 μm, 195 μm, 200 μm, 205 μm, 210 μm, 215 μm, 220 μm, 225 μm, 230 μm, 235 μm, or 240 μm. The products described herein can have a thickness of less than 170 μm. In some embodiments, the aluminum alloy capsule comprises a thickness of from about 30 μm to about 170 μm (e.g., from about 50 μm to less than about 150 μm or from about 75 μm to about 120 μm). For example, the aluminum alloy capsule can have a thickness of about 30 μm, 35 μm, 40 μm, 45 μm, 50 μm, 55 μm, 60 μm, 65 μm, 70 μm, 75 μm, 80 μm, 85 μm, 90 μm, 95 μm, 100 μm, 105 μm, 110 μm, 115 μm, 120 μm, 125 μm, 130 μm, 135 μm, 140 μm, 145 μm, 150 μm, 155 μm, 160 μm, 165 μm, or 170 μm. Optionally, the aluminum alloy capsule can comprise a thickness of from about 70 μm to 120 μm (e.g., from about 70 μm to less than about 110 μm or from about 80 μm to about 100 μm).
Turning to the figures, FIGS. 1A, 1B, 2A, and 2B show perspective views of beverage capsules according to various examples described herein. A capsule 100 includes a dome-shaped body 101. As shown with the examples illustrated in the figures, the height and curvature of the dome shape of body 101 may vary. The body 101 includes a lip 102 that extends from the body 101. As shown in FIG. 3, the body 101 defines cavity 104 that can house a substance 105. A cover 103 can span the opening of the cavity 104 and be secured with the lip 102 to seal the substance 105 within the cavity 104 of the capsule 100 until the capsule 100 is ready for use.

Aluminum Alloy Product Properties

The resulting metal products as described herein have a combination of desired properties, including high strength and high formability under O temper conditions. Under this temper condition, the aluminum alloy products can exhibit an ultimate tensile strength of from about 110 MPa to about 195 MPa (e.g., from about 170 MPa to less than about 185 MPa, from about 120 MPa to about 195 MPa, from about 125 MPa to about 145 MPa, or from about 165 MPa to about 195 MPa). For example, the ultimate tensile strength can be about 110 MPa, 115 MPa, 120 MPa, 125 MPa, 130 MPa, 135 MPa, 140 MPa, 145 MPa, 150 MPa, 155 MPa, 160 MPa, 165 MPa, 170 MPa, 175 MPa, 180 MPa, 185 MPa, 190 MPa, or 195 MPa. In some examples, the aluminum alloy product has a yield strength at 0.2% strain of from about 45 MPa to about 85 MPa (e.g., from about 75 MPa to less than about 85 MPa, from about 65 MPa to about 80 MPa, from about 45 MPa to about 75 MPa, or from about 55 MPa to about 85 MPa). For example, the yield strength can be about 45 MPa, 50 MPa, 55 MPa, 60 MPa, 65 MPa, 70 MPa, 75 MPa, 80 MPa, or 85 MPa. The aluminum alloy product can exhibit a total elongation using A100 test geometry of at least about 10% (e.g., at least about 13%, at least about 15%, at least about 17%, or at least about 18%). For example, the total elongation can be about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, or 22%, using A100 test geometry.
The aluminum alloys described herein may exhibit good earing property, which is a complex function of microstructure and process interactions, and good mechanical properties, even when down-gauged (e.g., thinner). For example, the aluminum alloy products may exhibit less than 2.0% earing in O temper. In certain examples, the aluminum alloy products exhibit less than 1.5% earing in O temper. For example, the aluminum alloy products can exhibit less than 2.0%, less than 1.9%, less than 1.8%, less than 1.7%, less than 1.6%, less than 1.5%, less than 1.4%, less than 1.3%, less than 1.2%, less than 1.1%, less than 1.0%, less than 0.9%, less than 0.8%, less than 0.7%, less than 0.6%, less than 0.5 earing, less than 0.4% earing, less than 0.3% earing, less than 0.2% earing, or less than 0.1% earing.
Table 1 shows properties of an aluminum alloy product according to examples described herein as compared to a conventional AA8011A product. For most aluminum alloys, higher strength provides a lower fracture resistance during deformation. The processability of these higher strength materials in the beverage capsule manufacturing process is unexpected.

TABLE 1

AA3104-O	AA3105-O	AA8011A-O

Ultimate Tensile	165-195 MPa	110-135 MPa	90-115 MPa
Strength
Yield Strength	65-85 MPa	45-75 MPa	35-55 MPa
Elongation	>10-13%	>10%	>17%

The increase in tensile and yield strengths noted in Table 1 may be retained during downgauging. The increased strength as compared to conventional products can reduce damage to the aluminum alloy products during transport and handling. In some examples, the increased tensile and yield strengths can enable use of expanded processing conditions, such as increased pressure in beverage machines, as compared to conventional products. Table 2 shows product ultimate tensile strength at various gauges of an aluminum alloy product according to one example described herein as compared to a conventional product (test width 15 mm).
TABLE 2

Thickness AA3104 AA8011A

100 μm — 150 MPa

90 μm 238 MPa —

80 μm 211 MPa —

70 μm 185 MPa —

The high tensile strength at reduced gauge can reduce raw material usage and operating costs as compared to conventional 8xxx series aluminum alloy products.
AA3104 aluminum alloys rolled down to a specific gauge and heat treated to a O temper can have a different combination of properties as shown in Table 3. Table 3 shows a standard can body stock sheet, AA3104 aluminum alloy, which was processed through hot and cold rolling to a final gauge of 90 μm and annealed to an O temper (Variant A), a similar alloy processed through a similar route where cold rolling thickness gauge reduction was decreased (Variant B), and finally a Variant C where both the cold rolling thickness gauge reduction was decreased and an intermediate heat treatment between cold reductions of 30% to 90% was performed at temperatures between 150° C. and 400° C. for more than 10 minutes.

TABLE 3

AA3104-O	Variant A	Variant B	Variant C

Tensile strength (MPa)	182	182	178
Yield strength (MPa)	93	89	83
Elongation, A100 (%)	11.9	11.5	12.2
Mean Earing (%)	2.18	2.01	1.44
% Cube + Goss texture	7.3	5.9	3.4

Earing is an important property for the manufacturing of beverage capsules because the cup top height profile is not trimmed or cut (as is the case for beverage cans) and can influence the ability to form the lip and subsequent processes for attaching the lid. Although each of the variants in Table 3 achieved similar tensile properties, only Variant C achieved the desired earing properties through a specific modification of the microstructure. The earing requirement for typical beverage capsules is that maximum values do not exceed 2%. Only Variant C achieved an earing value below 2%.
The earing values are related to the crystallographic distribution of grain orientation in the material, also called crystallographic texture. A lower earing value in an aluminum alloy may be achieved by balancing crystallographic orientations obtained during cold rolling, so-called Brass with Miller indices {011}<211>, S {123}<634> and Cu {112}<111>, with the Cube {001}<100> or Goss {011}<100> whose volume fraction are increased during recrystallization, for example, by annealing at a temperature above 300° C. The texture of typical can body stock 3104-H19 is very different from the texture of the aluminum alloys described herein. Table 4 shows the texture values of several variants for 3104-H19 and 3104-0. The microstructural threshold in terms of ratio of (Cube+Goss)/(Brass+S+Cu) can be targeted to achieve the specific earing properties.

TABLE 4

Cube + Goss	Brass + S + Cu	ratio

3104-H19	Variant 1	2.27	28.23	0.08
3104-H19	Variant 2	1.94	29.99	0.06
3104-O	Variant A	9.00	4.57	1.97
3104-O	Variant B	8.11	5.29	1.53
3104-O	Variant C	4.98	4.59	1.08

Methods of Making

The aluminum alloys described above may be cast into a cast product. Prior to casting, recycled scrap may be melted into liquid metal. Optionally, the liquid metal can be degassed to reduce the amount of hydrogen dissolved in the liquid metal. Any suitable degassing technique may be used. Optionally, an alloying element may be added to the liquid metal to form a modified liquid metal. In some examples, the alloying element comprises manganese and/or magnesium. Optionally, the alloying element may comprise silicon.
The alloys can be cast using any casting process performed according to standards commonly used in the aluminum industry as known to one of ordinary skill in the art. For example, the alloys may be cast using a continuous casting (CC) process that may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters. In some examples, the casting process is performed by a CC process to form a cast product such as a billet, slab, shate, strip, or the like. In some examples, the casting process is performed by a direct chill (DC) casting process to form a cast product such as an ingot. In some examples, the casting process is performed by strip casting. The cast product can then be subjected to further processing steps. Such processing steps include, but are not limited to, a heating step, a hot rolling step, a cold rolling step, and/or an annealing step. Optionally, the heating step can include homogenizing the cast aluminum alloy.
Heating
The heating step can include heating a cast aluminum alloy product, such as an ingot, prepared from an aluminum alloy composition to attain a peak metal temperature (PMT) of about, or at least about, 450° C. (e.g., at least about 460° C., at least about 470° C., at least about 480° C., at least about 490° C., at least about 500° C., at least about 510° C., at least about 520° C., at least about 530° C., at least about 540° C., at least about 550° C., at least about 560° C., at least about 570° C., at least about 580° C., at least about 590° C., at least about 600° C., or at least about 610° C.). For example, the cast aluminum alloy product can be heated to a temperature of from about 450° C. to about 610° C., from about 460° C. to about 590° C., from about 470° C. to about 580° C., from about 480° C. to about 565° C., from about 490° C. to about 555° C., or from about 500° C. to about 550° C. In some cases, the heating rate to the PMT can be about 100° C./hour or less, 75° C./hour or less, 50° C./hour or less, 40° C./hour or less, 30° C./hour or less, 25° C./hour or less, 20° C./hour or less, or 15° C./hour or less. In other cases, the heating rate to the PMT can be from about 10° C./min to about 100° C./min (e.g., from about 10° C./min to about 90° C./min, from about 10° C./min to about 70° C./min, from about 10° C./min to about 60° C./min, from about 20° C./min to about 90° C./min, from about 30° C./min to about 80° C./min, from about 40° C./min to about 70° C./min, or from about 50° C./min to about 60° C./min).
In some cases, the heating step includes homogenizing the cast aluminum alloy where the cast aluminum alloy product is allowed to soak (i.e., held at the indicated temperature) for a period of time. In some cases, the cast aluminum alloy product is allowed to soak for at least 30 minutes at a peak metal temperature as described above. According to one non-limiting example, the cast aluminum alloy product is allowed to soak for up to about 36 hours (e.g., from about 30 minutes to about 36 hours, inclusively). For example, the cast aluminum alloy product can be soaked at the peak metal temperature for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours, 26 hours, 27 hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours, 35 hours, 36 hours, or anywhere in between.
Hot Rolling and Cold Rolling
Following the homogenization step, a hot rolling step can be performed. The hot rolling step can include a hot reversing mill operation and/or a hot tandem mill operation. The hot rolling step can be performed at a temperature ranging from about 250° C. to about 600° C. (e.g., from about 300° C. to about 550° C. or from about 350° C. to about 450° C.), or any other suitable temperature. In some examples, the hot band gauge may be about 1.5 mm to about 10 mm (e.g., from about 2 mm to about 8 mm or from about 4 mm to about 6 mm). For example, the hot band gauge may be about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, about 9 mm, about 9.5 mm, or about 10 mm.
After hot rolling, a cold rolling step can optionally be applied to form an aluminum alloy product. For example, the cast aluminum alloy product can be cold rolled to a thickness of less than about 4 mm. In some examples, a sheet can have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. Optionally, the sheet gauge is less than about 240 μm (e.g., from about 170 μm to less than about 240 μm, from about 180 μm to about 230 μm, or from about 190 μm to about 220 μm). For example, the sheet can have a gauge of about 170 μm, 175 μm, 180 μm, 185 μm, 190 μm, 195 μm, 200 μm, 205 μm, 210 μm, 215 μm, 220 μm, 225 μm, 230 μm, 235 μm, or 240 μm. Optionally, the sheet gauge is less than about 170 μm (e.g., from about 30 μm to less than about 170 μm, from about 180 μm to about 230 μm, or from about 190 μm to about 220 μm). For example, the sheet can have a gauge of about 30 μm, 35 μm, 40 μm, 45 μm, 50 μm, 55 μm, 60 μm, 65 μm, 70 μm, 75 μm, 80 μm, 85 μm, 90 μm, 95 μm, 100 μm, 105 μm, 110 μm, 115 μm, 120 μm, 125 μm, 130 μm, 135 μm, 140 μm, 145 μm, 150 μm, 155 μm, 160 μm, 165 μm, or 170 μm.
In some examples, the cold rolling step can be applied using a plurality of passes with a step of interannealing the aluminum alloy product between the plurality of passes. In certain examples, the aluminum alloy product can be processed to a H18 or H19 temper before the annealing step to temper the aluminum alloy product.
Tempering
The processes of producing aluminum alloy products as disclosed herein may lead to an aluminum product that is recrystallized (e.g., O temper) and can be described as “soft” material. In some examples, the processes may include a thermal treatment including a full soft anneal as an intermediate and a final step to lead to an O-temper. Variant C differs from Variant A and B in that it includes both intermediate and final annealing whereas A and B only follow a final annealing process.
Degreasing
The process described herein can optionally include at least one degreasing step applied to the aluminum alloy product. The term “degreasing,” as used herein, includes processing the aluminum alloy product to remove residual oil accumulated on the surface from the hot rolling and cold rolling processes. The degreasing step can also remove residual surface debris, rolling oil, and aluminum fines from the rolling processes. The degreasing agent for use in the degreasing step can include water and/or solvents. In some cases, the degreasing agents can include acidic or alkaline agents. In some examples, the degreasing agent can be a phosphoric or sulfuric acid mixture with a fluoride compound. The pH of the acidic mixture can range from about 0 to about 5. In some examples, the degreasing agent can be a sodium hydroxide, sodium carbonate, potassium hydroxide, or potassium carbonate mixture. The pH of the basic mixture can range from about 8 to about 14. In certain examples, the degreasing agent can be a mild acidic or mild basic solution with a pH that can range from about 5.5 to about 7.5.

Methods of Using and Downstream Processing

The aluminum alloy products and methods described herein can be used for preparing packaging or any other desired application. In some examples, the aluminum alloy products and methods can be used to prepare beverage capsules. In some examples, the aluminum alloy products and methods can be used to food packaging or other product packaging products.

Illustrative Embodiments of Suitable Alloys, Products, and Methods

As used below, any reference to a series of illustrative alloys, products, or methods is to be understood as a reference to each of those alloys, products, or methods disjunctively (e.g., “Illustrative embodiments 1-4” is to be understood as “Illustrative embodiment 1, 2, 3, or 4”).
Illustrative embodiment 1 is an aluminum alloy capsule comprising a dome-shaped body comprising a lip that extends outwardly from the body, and a cover secured with the lip, wherein the body defines a cavity configured to contain a substance for preparation of a beverage and the cover forms a seal around the lip of the body to seal the substance within the body until the capsule is ready for use, and wherein at least one of the body and the cover comprise a 3xxx series aluminum alloy.
Illustrative embodiment 2 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy comprises AA3104.
Illustrative embodiment 3 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy comprises AA3105.
Illustrative embodiment 4 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy comprises at least 50 weight percent recycled aluminum.
Illustrative embodiment 5 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy comprises at least 80 weight percent recycled aluminum.
Illustrative embodiment 6 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the recycled aluminum comprises at least one of process run-around scrap, post-manufacturing scrap, or post-consumer scrap aluminum.
Illustrative embodiment 7 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy comprises at least one of manganese or magnesium.
Illustrative embodiment 8 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy is processed to produce an O temper alloy.
Illustrative embodiment 9 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy exhibits less than 2.0 percent earing in O temper.
Illustrative embodiment 10 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy exhibits a ratio of texture components (Cube+Goss)/(Brass+S+Cu) between 0.5 and 1.5.
Illustrative embodiment 11 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy exhibits less than 1.5 percent earing in O temper.
Illustrative embodiment 12 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the 3xxx series aluminum alloy exhibits a ratio of texture components (Cube+Goss)/(Brass+S+Cu) between 0.8 and 1.2.
Illustrative embodiment 13 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the aluminum alloy capsule comprises a thickness of 30 μm to 170 μm.
Illustrative embodiment 14 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the aluminum alloy capsule comprises a thickness of 70 μm to 120 μm. Illustrative embodiment 15 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the aluminum alloy has an ultimate tensile strength of 110 MPa to 195 MPa when the aluminum alloy is in O temper.
Illustrative embodiment 16 is the aluminum alloy capsule of any preceding or subsequent embodiment, wherein the aluminum alloy has a yield strength at 0.2 percent strain of 45 MPa to 85 MPa when the aluminum alloy is in O temper.
Illustrative embodiment 17 is the aluminum alloy capsule of any preceding embodiment, wherein the aluminum alloy has a total elongation of at least 10 percent when the aluminum alloy is in O temper.
Illustrative embodiment 18 is a method of producing an aluminum alloy product, comprising melting recycled aluminum into liquid metal, adding an alloying element to the liquid metal to form a modified liquid metal, the alloying element comprising at least one of manganese or magnesium, casting the modified liquid metal to form a cast aluminum alloy, wherein the modified liquid metal includes at least 50 weight percent recycled aluminum, heating the cast aluminum alloy, hot rolling the cast aluminum alloy to produce a rolled product comprising a thickness of 1.5 mm to 10 mm, cold rolling the rolled product to produce an aluminum alloy product comprising a thickness of from 30 μm to 170 μm, and annealing the aluminum alloy product to produce an O temper product.
Illustrative embodiment 19 is the method of any preceding or subsequent embodiment, wherein heating the cast aluminum alloy comprises homogenizing the cast aluminum alloy.
Illustrative embodiment 20 is the method of any preceding or subsequent embodiment, further comprising performing a plurality of passes during the cold rolling step and interannealing the aluminum alloy product between the plurality of passes of the cold rolling step.
Illustrative embodiment 21 is the method of any preceding or subsequent embodiment, wherein the product is processed to a H18 or H19 temper before the annealing step.
Illustrative embodiment 22 is the method of any preceding or subsequent embodiment, further comprising cleaning the aluminum alloy product with a mild alkaline or acidic agent after cold rolling the rolled product.
Illustrative embodiment 23 is the method of any preceding or subsequent embodiment, wherein the modified liquid metal comprises at least 80 weight percent recycled aluminum.
Illustrative embodiment 24 is the method of any preceding embodiment, wherein the recycled aluminum comprises at least one of process run-around scrap, post-manufacturing scrap, or post-consumer scrap aluminum.
Illustrative embodiment 25 is an aluminum alloy product prepared according to the method of any preceding embodiment.
Illustrative embodiment 26 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product comprises a 3xxx series aluminum alloy.
Illustrative embodiment 27 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product exhibits less than 2.0 percent earing when the aluminum alloy product is in O temper.
Illustrative embodiment 28 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product exhibits less than 1.5 percent earing when the aluminum alloy product is in O temper.
Illustrative embodiment 29 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product exhibits less than 1.0 percent earing when the aluminum alloy product is in O temper.
Illustrative embodiment 30 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product comprises a thickness of 70 μm to 120 μm.
Illustrative embodiment 31 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product has an ultimate tensile strength of 110 MPa to 195 MPa when the aluminum alloy product is in O temper.
Illustrative embodiment 32 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product has a yield strength at 0.2 percent strain of 45 MPa to 85 MPa when the aluminum alloy product is in O temper.
Illustrative embodiment 33 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product has a total elongation of at least 10 percent when the aluminum alloy product is in O temper.
Illustrative embodiment 34 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product is used for packaging.
Illustrative embodiment 35 is the aluminum alloy product of any preceding or subsequent embodiment, wherein the aluminum alloy product is a package for preparing a beverage.
Illustrative embodiment 36 is the aluminum alloy product of any preceding embodiment, wherein the aluminum alloy product is a beverage capsule.
All patents, publications, and abstracts cited above are incorporated herein by reference in their entireties. Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptions thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

1. An aluminum alloy capsule comprising:

a dome-shaped body comprising a lip that extends outwardly from the body; and

a cover secured with the lip,

wherein the body defines a cavity configured to contain a substance for preparation of a beverage and the cover forms a seal around the lip of the body to seal the substance within the body until the capsule is ready for use, and

wherein at least one of the body and the cover comprises a 3xxx series aluminum alloy.

2. The aluminum alloy capsule of claim 1, wherein the 3xxx series aluminum alloy comprises AA3104 or AA3105.

3. (canceled)

4. The aluminum alloy capsule of claim 1, wherein the 3xxx series aluminum alloy comprises at least 50 weight percent recycled aluminum.

5. (canceled)

6. The aluminum alloy capsule of claim 4, wherein the recycled aluminum comprises at least one of process run-around scrap, post-manufacturing scrap, or post-consumer scrap aluminum.

7. The aluminum alloy capsule of claim 1, wherein the 3xxx series aluminum alloy comprises at least one of manganese or magnesium.

8. The aluminum alloy capsule of claim 1, wherein the 3xxx series aluminum alloy is processed to produce an O temper alloy.

9. The aluminum alloy capsule of claim 8, wherein the 3xxx series aluminum alloy exhibits less than 2.0 percent earing in O temper.

10. The aluminum alloy capsule of claim 9, wherein the 3xxx series aluminum alloy exhibits a ratio of texture components (Cube+Goss)/(Brass+S+Cu) between 0.5 and 1.5.

11. (canceled)

12. (canceled)

13. The aluminum alloy capsule of claim 1, wherein the aluminum alloy capsule comprises a thickness of from 30 μm to 170 μm.

14. (canceled)

15. The aluminum alloy capsule of claim 1, wherein the aluminum alloy has an ultimate tensile strength of from 110 MPa to 195 MPa when the aluminum alloy is in O temper.

16. The aluminum alloy capsule of claim 1, wherein the aluminum alloy has a yield strength at 0.2 percent strain of from 45 MPa to 85 MPa when the aluminum alloy is in O temper.

17. The aluminum alloy capsule of claim 1, wherein the aluminum alloy has a total elongation of at least 13 percent when the aluminum alloy is in O temper.

18. A method of producing an aluminum alloy product, comprising:

melting recycled aluminum into liquid metal;

adding an alloying element to the liquid metal to form a modified liquid metal, the alloying element comprising at least one of manganese or magnesium;

casting the modified liquid metal to form a cast aluminum alloy, wherein the modified liquid metal includes at least 50 weight percent recycled aluminum;

heating the cast aluminum alloy;

hot rolling the cast aluminum alloy to produce a rolled product comprising a thickness of 1.5 mm to 10 mm;

cold rolling the rolled product to produce an aluminum alloy product comprising a thickness of from 30 μm to 170 μm; and

annealing the aluminum alloy product to produce an O temper product.

19. (canceled)

20. The method of claim 18, further comprising, performing a plurality of passes during the cold rolling step and interannealing the aluminum alloy product between the plurality of passes of the cold rolling step.

21. The method of claim 20, wherein the product is processed to a H18 or H19 temper before the annealing step.

22. The method of claim 18, further comprising cleaning the aluminum alloy product with a mild alkaline or acidic agent after cold rolling the rolled product.

23. (canceled)

24. (canceled)

25. An aluminum alloy product prepared according to the method of claim 18.

26. The aluminum alloy product of claim 25, wherein the aluminum alloy product comprises a 3xxx series aluminum alloy.

27-33. (canceled)

34. The aluminum alloy product of claim 25, wherein the aluminum alloy product is a package for preparing a beverage.

35. The aluminum alloy product of claim 25, wherein the aluminum alloy product is a beverage capsule.