WO2025133690A1

WO2025133690A1 - Cladded aluminum alloy product and method of manufacture

Info

Publication number: WO2025133690A1
Application number: PCT/IB2023/063204
Authority: WO
Inventors: Steven Kirkham; Fabian RITZ; Axel Alexander Maria Smeyers; Bernd JACOBY
Original assignee: Novelis Koblenz GmbH
Current assignee: Novelis Koblenz GmbH
Priority date: 2023-12-22
Filing date: 2023-12-22
Publication date: 2025-06-26
Anticipated expiration: 2026-06-22

Abstract

A cladded aluminum alloy product can include a wrought cladding layer and a sacrificial anode layer with a core layer therebetween. Optionally additional layers can be between the core layer between the wrought cladding layer and/or between the core layer and the sacrificial anode layer. The wrought cladding layer and sacrificial anode layer may each have an improved corrosion resistance and protect the core layer therebetween from corrosion.

Description

CLADDED ALUMINUM ALLOY PRODUCT AND

METHOD OF MANUFACTURE

FIELD

[0001] The disclosure is directed to cladded aluminum alloy products that include a core layer, a wrought cladding layer, and a sacrificial anode layer. The disclosure is also related to methods for producing said products.

BACKGROUND

[0002] Metal tubing used in heat exchangers is prone to exhibit corrosion over time. To address this problem, some commercially available forms of tubing are made from a zincated microport extrusion with a formed sheet product. In this process, the microport tubes are usually sprayed with pure zinc as the tubes exit the extrusion press. However, the coverage of the tubes with zinc can be inconsistent and the tubes are expensive to produce. Furthermore, these extrusions can exhibit softness in the post braze condition.

SUMMARY

[0003] 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.

[0004] Described herein are cladded aluminum alloy products comprising a core layer, a wrought cladding layer, and a sacrificial anode layer and methods of making said products. In an aspect, a method for producing a cladded aluminum alloy can comprise joining the core layer, the wrought cladding layer, and the sacrificial anode layer such that the core layer is between the wrought cladding layer and the sacrificial anode layer. The wrought cladding layer can comprise an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum. [0005] In some instances, the cladded aluminum alloy product further comprises an interlayer between the core layer and the wrought cladding layer, and the joining step includes (i) assembling the interlayer onto a first surface of the core layer, assembling the wrought cladding layer onto the interlayer, and assembling the sacrificial anode layer onto a second surface of the core layer, wherein the first surface and the second surface of the core layer are on opposing sides of the core layer, and (ii) hot roll bonding the assembled layers. Alternatively, the joining step includes (i) assembling the wrought cladding layer onto a first surface of the core layer, and assembling the sacrificial anode layer onto a second surface of the core layer, wherein the first surface and the second surface of the core layer are on opposing sides of the core layer, and (ii) hot roll bonding the assembled layers.

[0006] The process can further include casting the aluminum alloy; and rolling the cast aluminum alloy to a required thickness, thus producing the wrought cladding layer.

[0007] In some instances, the core layer is a wrought core layer, and the sacrificial anode layer is a wrought sacrificial anode layer. In some examples, the core layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.3 wt. % silicon, up to 1 wt. % iron, 0.05 wt. % to 1.2 wt. % copper, 0.6 wt. % to 2 wt. % manganese, up to 0.5 wt. % magnesium, up to 0.3 wt. % chromium, up to 0.5 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum. In some examples, the sacrificial anode layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.5 wt. % silicon, 0.05 wt. % to 2 wt. % iron, up to 0.3 wt. % copper, up to 1.8 wt. % manganese, up to 3 wt. % magnesium, up to 0.3 wt. % chromium, up to 6 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum.

[0008] A product can be fabricated by a process that includes any of the foregoing processes. Said product can be a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and/or a manifold or assembly thereof.

[0009] Another example process for joining two or more aluminum forms by brazing can include assembling and securing the two or more aluminum forms together, wherein at least one of the two or more aluminum forms is a cladded aluminum alloy product comprising a core layer, a wrought cladding layer, and a sacrificial anode layer with the core layer between the wrought cladding layer and the sacrificial anode layer; heating the two or more aluminum forms, including the wrought cladding layer, to a brazing temperature until joints are created among the two or more aluminum forms by capillary forces; and cooling the two or more aluminum forms below solidus temperature of the wrought cladding layer. The wrought cladding layer can comprise an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum. In some instances, the core layer is a wrought core layer, and the sacrificial anode layer is a wrought sacrificial anode layer. In some examples, the core layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.3 wt. % silicon, up to 1 wt. % iron, 0.05 wt. % to 1.2 wt. % copper, 0.6 wt. % to 2 wt. % manganese, up to 0.5 wt. % magnesium, up to 0.3 wt. % chromium, up to 0.5 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum. In some examples, the sacrificial anode layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.5 wt. % silicon, 0.05 wt. % to 2 wt. % iron, up to 0.3 wt. % copper, up to 1.8 wt. % manganese, up to 3 wt. % magnesium, up to 0.3 wt. % chromium, up to 6 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum. [0010] In the foregoing process, the brazing temperature can, for example, be from 570 °C to 620 °C. In some instances, the brazing is a controlled atmosphere brazing, and wherein the aluminum alloy of the wrought cladding layer comprises up to 0.3 wt. % magnesium. Alternatively, the brazing is a vacuum brazing, and wherein the aluminum alloy of the wrought cladding layer comprises from 0.2 wt. % to 1.5 wt. % magnesium.

[0011] A cladded aluminum alloy product can include a core layer; a wrought cladding layer; and a sacrificial anode layer; wherein the core layer is between the wrought cladding layer and the sacrificial anode layer. The wrought cladding layer can comprise an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum. In some instances, the core layer is a wrought core layer, and the sacrificial anode layer is a wrought sacrificial anode layer. In some examples, the core layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.3 wt. % silicon, up to 1 wt. % iron, 0.05 wt. % to 1.2 wt. % copper, 0.6 wt. % to 2 wt. % manganese, up to 0.5 wt. % magnesium, up to 0.3 wt. % chromium, up to 0.5 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum. In some examples, the sacrificial anode layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.5 wt. % silicon, 0.05 wt. % to 2 wt. % iron, up to 0.3 wt. % copper, up to 1.8 wt. % manganese, up to 3 wt. % magnesium, up to 0.3 wt. % chromium, up to 6 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum.

[0012] In some instances, the cladded aluminum alloy product can further include an interlayer between the core layer and the wrought cladding layer. Alternatively, the wrought cladding layer is brazed directly to the core layer.

[0013] In some instances, the sacrificial anode layer is brazed directly to the core layer.

[0014] A product can be fabricated using any of the foregoing cladded aluminum alloy products. The resultant product can be a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and/or a manifold or assembly thereof.

[0015] Further aspects, objects, and advantages of the invention will become apparent upon consideration of the detailed description that follow.

DETAILED DESCRIPTION OF THE INVENTION

[0016] The disclosure is directed to cladded aluminum alloy products that include a core layer, a wrought cladding layer, a sacrificial anode layer, and optionally additional layers. Generally, the core layer is between the wrought cladding layer and the sacrificial anode layer where additional layers may be located between the core layer and the wrought cladding layer and/or between the core layer and the sacrificial anode layer. The disclosure is also related to methods for producing said products.

[0017] Advantageously, the wrought cladding layer and sacrificial anode layer may be composed of aluminum alloys having improved corrosion resistance and protect the core layer therebetween from corrosion. The core layer primarily contributes to the mechanical properties of the cladded aluminum alloy product. Accordingly, reducing corrosion of the core layer may increase the lifetime of the cladded aluminum alloy product.

[0018] Further, using a wrought cladding layer, as compared to a cladding layer produce by direct casting (i.e., directly casting to a sheet using a mold), improves bonding between the wrought cladding layer and the core by reducing clad-core blistering. The improved bonding may allow for thinner wrought cladding layers, which may reduce the overall thickness of the cladded aluminum alloy products.

[0019] Further, any of the layers of the cladded aluminum alloy products can be produced using recycled aluminum. The use of recycled aluminum in producing a layer reduces the energy consumption because less, if any, prime aluminum is needed. Accordingly, not only would such aluminum alloys have a lower carbon footprint as a consequence of the high recycled content, but an additional positive effect is a much lower energy consumption compared to standard amount of energy used when low carbon prime aluminum is produced.

Definitions and Descriptions

[0020] 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.

[0021] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0022] As used herein, the meaning of “metals” includes pure metals, alloys and metal solid solutions unless the context clearly dictates otherwise.

[0023] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “4xxx .” 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.

[0024] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum alloy product having a thickness of greater than 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.

[0025] 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 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. [0026] As used herein, a sheet generally refers to an aluminum alloy product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than 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.

[0027] 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.”

[0028] 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.

[0029] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

[0030] 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.

[0031] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C. As used herein, the meaning of “ambient conditions” can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about

28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about

43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about

73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about

88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.

[0032] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt. %).

Aluminum Alloy Compositions

[0033] Core Layer

[0034] Aluminum alloys suitable for use in the core layer of the compositions, products, and methods described herein can, for example, have the following elemental composition as provided in Table 1.

Table 1

In some examples, the aluminum alloy for optional use as a core layer can have the following elemental composition as provided in Table 2.

Table 2

[0035] In some examples, the aluminum alloy for optional use as a core layer can have the following elemental composition as provided in Table 3.

Table 3

[0036] In some examples, the aluminum alloy for optional use as a core layer can have the following elemental composition as provided in Table 4.

Table 4

[0037] In some examples, the aluminum alloy for optional use as a core layer can have the following elemental composition as provided in Table 5. Table 5

[0038] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 1-5, the predominant element is aluminum (Al), sometimes called “remainder Al.” In other words, the term “remainder” can be used to describe predominant aluminum (Al) content in the aluminum alloys described herein.

[0039] In certain examples, the disclosed aluminum alloy used in the core layer includes silicon (Si) in an amount from about 0.05 % to about 1.3 % (e.g., from 0.1 to 1.3 %, from 0.5 % to 1.3 %, from 0.8 % to 1.3 %, or from 0.9 % to 1.2 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, or 1.30 % Si. All expressed in wt. % based on the total weight of the aluminum alloy.

[0040] In certain examples, the disclosed aluminum alloy used in the core layer includes iron (Fe) in an amount of up to about 1.0 % (e.g., from 0 % to 1.0 %, from 0.05 % to 1.0 %, from 0.05 % to 0.8%, from 0.05 % to 0.6 %, from 0.05 % to 0.5 %, or from 0.05 % to 0.4 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %,

0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %,

0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %,

0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %,

0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %,

0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %,

0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, or 1.00 % Fe. In some cases, the disclosed alloy does not include Fe (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0041] In certain examples, the disclosed aluminum alloy used in the core layer includes copper (Cu) in an amount from about 0.05 % to about 1.2 % (e.g., from 0.1 % to 1.2 %, from 0.1 % to 1.0 %, from 0.1 % to 0.8 %, from 0.1 % to 0.6 %, or from 0.2 % to 0.5 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, or 1.20 % Cu. All expressed in wt. % based on the total weight of the aluminum alloy.

[0042] In certain examples, the disclosed aluminum alloy used in the core layer includes manganese (Mn) in an amount from about 0.6 % to about 2.0 % (e.g., from 0.6 % to 1.8 %, from 0.9 % to 2.0 %, from 1.2 % to 1.8 %, or from 1.4 % to 1.5 %) based on the total weight of the alloy. For example, the alloy can include 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95 %, or 2.00 % Mn. All expressed in wt. % based on the total weight of the aluminum alloy.

[0043] In certain examples, the disclosed aluminum alloy used in the core layer includes magnesium (Mg) in an amount of up to about 0.5 % (e.g., from 0 % to 0.5 %, from 0.005 % to 0.50 %, from 0.005 % to 0.40 %, from 0.005 % to 0.30 %, from 0.005 % to 0.20 %, from 0.005 % to 0.15 %, or from 0.005 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, 0.300 %, 0.305 %, 0.310 %, 0.315 %, 0.320 %, 0.325 %, 0.330 %, 0.335 %, 0.340 %, 0.345 %, 0.350 %, 0.355 %, 0.360 %, 0.365 %, 0.370 %, 0.375 %, 0.380 %, 0.385 %, 0.390 %, 0.395 %, 0.400 %, 0.405 %, 0.410 %, 0.415 %, 0.420 %, 0.425 %, 0.430 %, 0.435 %, 0.440 %, 0.445 %, 0.450 %, 0.455 %, 0.460 %, 0.465 %, 0.470 %, 0.475 %, 0.480 %, 0.485 %, 0.490 %, 0.495 %, or 0.500 % Mg. In some cases, the disclosed alloy does not include Mg (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0044] In certain aspects, the disclosed aluminum alloy used in the core layer includes chromium (Cr) in an amount of up to about 0.3 % (e.g., from 0 % to 0.30 %, from 0.001 % to 0.25 %, from 0.001 % to 0.20 %, from 0.001 % to 0.15 %, from 0.001 % to 0.10 %, from 0.001 % to 0.05 %, or from 0.001 % to 0.03 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Cr. In some cases, the disclosed alloy does not include Cr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0045] In certain examples, the disclosed aluminum alloy used in the core layer includes zinc (Zn) in an amount of up to about 0.5 % (e.g., from 0 % to 0.5 %, from 0.001 % to 0.50 %, from 0.001 % to 0.40 %, from 0.001 % to 0.30 %, from 0.001 % to 0.20 %, from 0.001 % to 0.10 %, or from 0.001 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, 0.300 %, 0.305 %, 0.310 %, 0.315 %, 0.320 %, 0.325 %, 0.330 %, 0.335 %, 0.340 %, 0.345 %, 0.350 %, 0.355 %, 0.360 %, 0.365 %, 0.370 %, 0.375 %, 0.380 %, 0.385 %, 0.390 %, 0.395 %, 0.400 %, 0.405 %, 0.410 %, 0.415 %, 0.420 %, 0.425 %, 0.430 %, 0.435 %, 0.440 %, 0.445 %, 0.450 %, 0.455 %, 0.460 %, 0.465 %, 0.470 %, 0.475 %, 0.480 %, 0.485 %, 0.490 %, 0.495 %, or 0.500 % Zn. In some cases, the disclosed alloy does not include Zn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0046] In certain aspects, the disclosed aluminum alloy used in the core layer includes titanium (Ti) in an amount of up to about 0.3 % (e.g., from 0 % to 0.30 %, from 0.001 % to 0.25 %, from 0.001 % to 0.20 %, from 0.001 % to 0.15 %, from 0.001 % to 0.10 %, from 0.001 % to 0.05 %, or from 0.001 % to 0.03 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Ti. In some cases, the disclosed alloy does not include Ti (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0047] In certain aspects, the disclosed aluminum alloy used in the core layer includes zirconium (Zr) in an amount of up to about 0.3 % (e.g., from 0 % to 0.30 %, from 0.001 % to 0.25 %, from 0.001 % to 0.20 %, from 0.001 % to 0.15 %, from 0.001 % to 0.10 %, from 0.001 % to 0.05 %, or from 0.001 % to 0.01 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Zr. In some cases, the disclosed alloy does not include Zr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0048] In certain aspects, the disclosed aluminum alloy used in the core layer includes vanadium (V) in an amount of up to about 0.3 % (e.g., from 0 % to 0.30 %, from 0.001 % to 0.25 %, from 0.001 % to 0.20 %, from 0.001 % to 0.15 %, from 0.001 % to 0.10 %, from 0.001 % to 0.05 %, or from 0.001 % to 0.01 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % V. In some cases, the disclosed alloy does not include V (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0049] Optionally, the alloy can further include other minor elements, sometimes referred to as impurities, in amounts of about 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below or each of said impurities. These impurities may include, but are not limited to, scandium (Sc), nickel (Ni), yttrium (Y), hafnium (Hf), thallium (Th), gallium (Ga), tin (Sn), lead (Pb), bismuth (Bi), strontium (Sr), calcium (Ca), or combinations thereof. Accordingly, Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, or Ca, if present, may each independently 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. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., does not exceed 0.10 %, or does not exceed 0.05 %). In certain aspect, the apply compositions may be devoid of (not comprise or comprise at 0.00 %) one or more of: Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, and Ca. All expressed in wt. % based on the total weight of the aluminum alloy.

[0050] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder Al.

[0051] Regarding the composition of the core layer, any alloy designated as a 3xxx series aluminum alloy, a 5xxx series aluminum alloy, or a 6xxx series aluminum alloy including modified versions thereof is suitable for use as the core layer. For example, in some instances, a 3xxx series aluminum alloys suitable for use as the core layer may have higher levels of Cu.

[0052] Non-limiting examples of 3xxx series aluminum alloys for use in the core layers described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, and AA3065. Non-limiting examples of 5xxx series aluminum alloys for use in the core layers described herein can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, and AA5088.

[0053] Non-limiting examples of 6xxx series aluminum alloys for use in the core layers described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, and AA6092.

[0054] The aluminum alloys for the core layers of the present disclosure can be fabricated from recycled content. In some aspects, the aluminum alloy of the core layer can contain at least about 10 wt. % recycled content (e.g., at least about 15 wt. % recycled content, at least about 20 wt. % recycled content, at least about 25 wt. % recycled content, at least about 30 wt. % recycled content, at least about 35 wt. % recycled content, at least about 40 wt. % recycled content, at least about 45 wt. % recycled content, at least about 50 wt. % recycled content, at least about 55 wt. % recycled content, or at least about 60 wt. % recycled content). [0055] Cladding Layer

[0056] Described below are 4xxx series aluminum alloys suitable for use as in a cladding layer. The 4xxx series aluminum alloys can have the following elemental composition as provided in Table 6.

Table 6

[0057] In other examples, the 4xxx series aluminum alloys can have the following elemental composition as provided in Table 7.

Table 7

[0058] In other examples, the 4xxx series aluminum alloys can have the following elemental composition as provided in Table 8.

Table 8

[0059] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 6-8, the predominant element is Al, sometimes called “remainder Al.” In other words, the term “remainder” can be used to describe predominant aluminum (Al) content in the aluminum alloys described herein.

[0060] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Si in an amount from about 6 % to about 13 % (e.g., from 6 % to 10 %, from 7 % to 11 %, from 8 % to 12 %, or from 9 % to 13 %) based on the total weight of the alloy. For example, the alloy can include 6.0 %, 6.2 %, 6.4 %, 6.6 %, 6.8 %, 7.0 %, 7.2 %, 7.4 %, 7.6 %, 7.8 %, 8.0 %, 8.2 %, 8.4 %, 8.6 %, 8.8 %, 9.0 %, 9.2 %, 9.4 %, 9.6 %, 9.8 %, 10.0 %, 10.2 %, 10.4 %, 10.6 %, 10.8 %, 11.0 %, 11.2 %, 11.4 %, 11.6 %, 11.8 %, 12.0 %, 12.2 %, 12.4 %, 12.6 %, 12.8 %, or 13.0 % Si. All expressed in wt. % based on the total weight of the aluminum alloy. [0061] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Fe in an amount from about 0.1 % to about 0.7 % (e.g., from 0.1 % to 0.6 %, from 0.2 % to 0.6 %, from 0.1 % to 0.5 %, from 0.2 % to 0.5 %, or from 0.2 % to 0.4 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24

%, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %, 0.35

%, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46

%, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57

%, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68

%, 0.69 %, or 0.70 % Fe. All expressed in wt. % based on the total weight of the aluminum alloy.

[0062] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Cu in an amount from about 0.1 % to about 1.5 % (e.g., from 0.2 % to 1.5 %, from 0.2 % to 1.25 %, from 0.2 % to 1 %, or from 0.2 % to 0.75 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05%, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, or 1.50 % Cu. All expressed in wt. % based on the total weight of the aluminum alloy.

[0063] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Mn in an amount from about 0.1 % to about 1.9 % (e.g., from 0.3 % to 1.5 %, from 0.4 % to 1.25 %, from 0.75 % to 1.25 %, or from 1.0 % to 1.25 %) based on the total weight of the alloy. For example, the alloy can include 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 0.95 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, or 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, or 1.90 % Mn. All expressed in wt. % based on the total weight of the aluminum alloy.

[0064] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Mg in an amount of up to about 2 % (e.g., from 0 % to 2 %, from 0.01 % to 2 %, from 0.01 % to 0.2 %, from 0.01 % to 0.1 %, from 0.2 % to 1.5 %, from 0.2 % to 1.5 %, or from 0.5 % to 2 %) based on the total weight of the alloy. For example, the alloy can include

0.01 %, 0.05 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %,

0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %,

1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95 %, or 2.00 % Mg. In some cases, the disclosed alloy does not include Mg (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0065] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes Cr in an amount of up to about 0.1 % (e.g., from 0 % to 0.1 %, from 0.01 % to 0.1 %, from 0.01 % to 0.07 %, or from 0.01 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, or 0.10 % Cr. In some cases, the disclosed alloy does not include Cr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0066] In certain examples, the disclosed aluminum alloy used in the cladding layer includes Zn in an amount of up to about 3 % (e.g., from 0 % to 3 %, from 0.01 % to 3 %, from 0.01 % to 2 %, from 0.01 % to 1 %, from 0.01 % to 0.5 %, or from 0.01 % to 0.01 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.05 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %,

0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %,

1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %,

1.85 %, 1.90 %, 1.95 %, 2.00 %, 2.05 %, 2.10 %, 2.15 %, 2.20 %, 2.25 %, 2.30 %, 2.35 %,

2.40 %, 2.45 %, 2.50 %, 2.55 %, 2.60 %, 2.65 %, 2.70 %, 2.75 %, 2.80 %, 2.85 %, 2.90 %,

2.95 %, or 3.00 % Zn. In some cases, the disclosed alloy does not include Zn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0067] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes Ti in an amount of up to about 0.2 % (e.g., from 0 % to 0.2 %, from 0.01 % to 0.2 %, from 0.01 % to 0.1 %, or from 0.05 % to 0.15 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, or 0.200 % Ti. In some cases, the disclosed alloy does not include Ti (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy. [0068] In certain aspects, the disclosed aluminum alloy used in the cladding layer includes Zr in an amount of up to about 0.1 % (e.g., from 0 % to 0.1 %, from 0.01 % to 0.1 %, from 0.01 % to 0.07 %, or from 0.01 % to 0.05 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, or 0.10 % Zr. In some cases, the disclosed alloy does not include Zr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0069] Optionally, the disclosed aluminum alloy used in the cladding layer can further include other minor elements, sometimes referred to as impurities, in amounts of about 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below or each of said impurities. These impurities may include, but are not limited to, Sc, V, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, Ca, or combinations thereof. Accordingly, Sc, V, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, or Ca, if present, may each independently 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. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., does not exceed 0.10 %, or does not exceed 0.05 %). In certain aspect, the apply compositions may be devoid of (not comprise or comprise at 0.00 %) one or more of: Sc, V, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, and Ca. All expressed in wt. % based on the total weight of the aluminum alloy.

[0070] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder Al.

[0071] Non-limiting exemplary 4xxx series aluminum alloys for use in the cladding layers described herein can include AA4004, A4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0072] The 4xxx series aluminum alloys of the present disclosure can be fabricated from recycled content. In some aspects, the aluminum alloy can contain at least about 10 wt. % recycled content (e.g., at least about 15 wt. % recycled content, at least about 20 wt. % recycled content, at least about 25 wt. % recycled content, at least about 30 wt. % recycled content, at least about 35 wt. % recycled content, at least about 40 wt. % recycled content, at least about 45 wt. % recycled content, at least about 50 wt. % recycled content, at least about 55 wt. % recycled content, or at least about 60 wt. % recycled content).

[0073] Sacrificial Anode Cladding Layer

[0074] Described below are aluminum alloys suitable for use as in a sacrificial anode cladding layer, which can have the following elemental composition as provided in Table 9. Table 9

[0075] In other examples, the aluminum alloys suitable for use as in a sacrificial anode cladding layer can have the following elemental composition as provided in Table 10.

Table 10

[0076] In other examples, aluminum alloys suitable for use as in a sacrificial anode cladding layer can have the following elemental composition as provided in Table 11.

Table 11

[0077] It is to be understood that, in various embodiments of the alloys described herein, including those in Tables 6-8, the predominant element is Al, sometimes called “remainder Al.” In other words, the term “remainder” can be used to describe predominant aluminum (Al) content in the aluminum alloys described herein.

[0078] In certain examples, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Si in an amount from about 0.05 % to about 1.5 % (e.g., from 0.05 % to 1.4 %, from 0.05 % to 1.3 %, or from 0.05 % to 1.2 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, or 1.50 % Si. All expressed in wt. % based on the total weight of the aluminum alloy.

[0079] In certain examples, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Fe in an amount from about 0.05 % to about 2.0 % (e.g., from 0.05 % to 1.9 %, from 0.05 % to 1.8 %, from 0.05 % to 1.7 %, from 0.05 % to 1.6 %, or from 0.05 % to 1.5 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95 %, or 2.00 % Fe. All expressed in wt. % based on the total weight of the aluminum alloy.

[0080] In certain examples, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Cu in an amount of up to about 0.30 % (e.g., from 0 % to 0.30 %, from 0.001 % to 0.25 %, from 0.001 % to 0.20 %, or from 0.001 % to 0.10 %) based on the total weight of the alloy. For example, the alloy can include 0.001 %, 0.005 %, 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Cu. In some cases, the disclosed alloy does not include Cu (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0081] In certain examples, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Mn in an amount of up to about 1.8 % (e.g., from 0 % to 1.8 %, from 0.05 % to 1.8 %, from 0.05 % to 1.7 %, or from 0.05 % to 1.5 %) based on the total weight of the alloy. For example, the alloy can include 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30

%, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80 %, 0.85

%, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40 %, 1.45

%, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, or 1.80 % Mn. In some cases, the disclosed alloy does not include Mn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0082] In certain examples, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Mg in an amount of up to about 3.0 % (e.g., from 0 % to 3.0 %, from 0.01 % to 3.0 %, from 0.05 % to 2.0 %, or from 0.05 % to 1.5 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %, 0.70 %, 0.75 %, 0.80

%, 0.85 %, 0.90 %, 1.00 %, 1.05 %, 1.10 %, 1.15 %, 1.20 %, 1.25 %, 1.30 %, 1.35 %, 1.40

%, 1.45 %, 1.50 %, 1.55 %, 1.60 %, 1.65 %, 1.70 %, 1.75 %, 1.80 %, 1.85 %, 1.90 %, 1.95

%, 2.00 %, 2.05 %, 2.10 %, 2.15 %, 2.20 %, 2.25 %, 2.30 %, 2.35 %, 2.40 %, 2.45 %, 2.50 %, 2.55 %, 2.60 %, 2.65 %, 2.70 %, 2.75 %, 2.80 %, 2.85 %, 2.90 %, 2.95 %, or 3.00 %. In some cases, the disclosed alloy does not include Mg (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0083] In certain aspects, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Cr in an amount of up to about 0.30 % (e.g., from 0 % to 0.30 %, from 0.01 % to 0.30 %, from 0.05 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075 %, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Cr. In some cases, the disclosed alloy does not include Cr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0084] In certain examples, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Zn in an amount up to about 6.0 % (e.g., from 0.01 % to 6.0 %, from 0.01 % to 0.50 %, from 0.01 % to 3.0 %, from 2.0 % to 5.0 %, from 3.0 % to 6.0 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.05 %, 0.10 %, 0.15 %, 0.20 %, 0.25 %, 0.30 %, 0.35 %, 0.40 %, 0.45 %, 0.50 %, 0.55 %, 0.60 %, 0.65 %,

2.95 %, 3.00 %, 3.05 %, 3.10 %, 3.15 %, 3.20 %, 3.25 %, 3.30 %, 3.35 %, 3.40 %, 3.45 %,

3.50 %, 3.55 %, 3.60 %, 3.65 %, 3.70 %, 3.75 %, 3.80 %, 3.85 %, 3.90 %, 3.95 %, 4.00 %,

4.05 %, 4.10 %, 4.15 %, 4.20 %, 4.25 %, 4.30 %, 4.35 %, 4.40 %, 4.45 %, 4.50 %, 4.55 %,

4.60 %, 4.65 %, 4.70 %, 4.75 %, 4.80 %, 4.85 %, 4.90 %, 4.95 %, 5.00 %, 5.05 %, 5.10 %,

5.15 %, 5.20 %, 5.25 %, 5.30 %, 5.35 %, 5.40 %, 5.45 %, 5.50 %, 5.55 %, 5.60 %, 5.65 %,

5.70 %, 5.75 %, 5.80 %, 5.85 %, 5.90 %, 5.95 %, or 6.00 % Zn. In some cases, the disclosed alloy does not include Zn (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy. [0085] In certain aspects, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Ti in an amount of up to about 0.30 % (e.g., from 0 % to 0.30 %, from 0.01 % to 0.30 %, from 0.05 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %,

0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075

%, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170

%, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %,

0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Ti. In some cases, the disclosed alloy does not include Ti (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0086] In certain aspects, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes Zr in an amount of up to about 0.30 % (e.g., from 0 % to 0.30 %, from 0.01 % to 0.30 %, from 0.05 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075

%, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %,

0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170

0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % Zr. In some cases, the disclosed alloy does not include Zr (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0087] In certain aspects, the disclosed aluminum alloy used in the sacrificial anode cladding layer includes V in an amount of up to about 0.30 % (e.g., from 0 % to 0.30 %, from 0.01 % to 0.30 %, from 0.05 % to 0.25 %, or from 0.10 % to 0.20 %) based on the total weight of the alloy. For example, the alloy can include 0.010 %, 0.015 %, 0.020 %, 0.025 %, 0.030 %, 0.035 %, 0.040 %, 0.045 %, 0.050 %, 0.055 %, 0.060 %, 0.065 %, 0.070 %, 0.075

%, 0.080 %, 0.085 %, 0.090 %, 0.095 %, 0.100 %, 0.105 %, 0.110 %, 0.115 %, 0.120 %, 0.125 %, 0.130 %, 0.135 %, 0.140 %, 0.145 %, 0.150 %, 0.155 %, 0.160 %, 0.165 %, 0.170 %, 0.175 %, 0.180 %, 0.185 %, 0.190 %, 0.195 %, 0.200 %, 0.205 %, 0.210 %, 0.215 %, 0.220 %, 0.225 %, 0.230 %, 0.235 %, 0.240 %, 0.245 %, 0.250 %, 0.255 %, 0.260 %, 0.265 %, 0.270 %, 0.275 %, 0.280 %, 0.285 %, 0.290 %, 0.295 %, or 0.300 % V. In some cases, the disclosed alloy does not include V (i.e., 0 %). All expressed in wt. % based on the total weight of the aluminum alloy.

[0088] Optionally, the disclosed aluminum alloy used in the sacrificial anode cladding layer can further include other minor elements, sometimes referred to as impurities, in amounts of about 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below or each of said impurities. These impurities may include, but are not limited to, Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, Ca, or combinations thereof. Accordingly, Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, or Ca, if present, may each independently 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. In certain aspects, the sum of all impurities does not exceed 0.15 % (e.g., does not exceed 0.10 %, or does not exceed 0.05 %). In certain aspect, the apply compositions may be devoid of (not comprise or comprise at 0.00 %) one or more of: Sc, Ni, Y, Hf, Th, Ga, Sn, Pb, Bi, Sr, and Ca. All expressed in wt. % based on the total weight of the aluminum alloy.

[0089] The remaining percentage of the aluminum alloy may be aluminum, e.g., remainder Al.

[0090] Non-limiting examples of Ixxx series aluminum alloys for use in the sacrificial anode cladding layers described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, and AA1199. Preferably the aluminum alloy of the sacrificial anode cladding layer is a Ixxx series aluminum alloy with less than 0.5 wt. % zinc.

[0091] The aluminum alloys used in the sacrificial anode cladding layer of the present disclosure can be fabricated from recycled content. In some aspects, the aluminum alloy can contain at least about 10 wt. % recycled content (e.g., at least about 15 wt. % recycled content, at least about 20 wt. % recycled content, at least about 25 wt. % recycled content, at least about 30 wt. % recycled content, at least about 35 wt. % recycled content, at least about 40 wt. % recycled content, at least about 45 wt. % recycled content, at least about 50 wt. % recycled content, at least about 55 wt. % recycled content, or at least about 60 wt. % recycled content). Methods of Preparing Aluminum Alloy Products

[0092] The aluminum alloys described herein for use in the wrought cladding layers, the core layers, the sacrificial anode layers, and any other optional layers can be cast using any suitable casting method. For example, the aluminum alloys can be used to cast various metallic cast products, such as billets, ingots, or strips. Methods of producing an aluminum sheet are also described herein. The aluminum alloy can be cast and then further processing steps may be performed. In some examples, the processing steps include a casting step, a preheating and/or a homogenizing step, one or more hot rolling steps, and one or more cold rolling steps.

[0093] For example, when preparing a layer described herein, a co-cast ingot or other cast product can be processed by any means known to those of ordinary skill in the art. Optionally, the processing steps can be used to prepare sheets. Such processing steps include, but are not limited to, homogenizing, pre-heating, hot rolling, cold rolling, and stretching or sawing, as known to those of ordinary skill in the art. A homogenization step and a cold rolling step are typically not used in preparing a cladding layer. Advantageously, the use of recycled material may reduce the CO2 footprint required to produce the layer as compared to similar layers produced principally using prime aluminum. Cladding layers can also be produced by sawing from a cast ingot to final format without any rolling steps.

[0094] A hot rolling step can be performed. The ingots can then be hot rolled at a temperature between 300 °C to 500 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge of from about 3 mm to about 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature of from about 300 °C to about 450 °C. For example, the continuously cast product can be allowed to cool to a temperature of from about 325 °C to about 425 °C or from about 350 °C to about 400 °C. The continuously cast product can then be hot rolled at a temperature of from about 300 °C to about 450 °C to form a hot rolled plate, a hot rolled shate, or a hot rolled sheet having a gauge of from about 3 mm to about 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled product upon exit from the hot rolling mill is no more than about 470 °C, no more than about 450 °C, no more than about 440 °C, or no more than about 430 °C.

[0095] Additional processing for the plate, shate, coil, or sheet can include stretching, sawing, grinding, and the like.

[0096] When preparing a cladded aluminum alloy product, the aluminum alloys described herein can be cast into ingots using a direct chill (DC) process, a continuous casting (CC) process, or electromagnetic casting (EMC) process. The DC casting process is performed according to standards commonly used in the aluminum industry as known to one of skill in the art. The CC casting process can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0097] The cast aluminum alloy product can be processed by any means known to those of ordinary skill in the art. Optionally, the cast aluminum alloy product can be processed, using processing steps as described herein, to prepare sheets, plates, or shates. Example processing steps include, but are not limited to, pre-heating, hot rolling, cold rolling, and/or annealing. One or more of the steps of solution heat treatment, pre-aging, and/or artificial aging may be excluded when processing the cladded aluminum alloy product.

[0098] In a pre-heating step, a cast product may be heated to a pre-heating temperature, such as a temperature ranging from about 400 °C to about 630 °C (e.g., 400 °C to 500 °C, 450 °C to 570 °C, or 500 °C to 630 °C). For example, the cast product can be heated to a temperature of 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, 450 °C, 460 °C, 470 °C, 480 °C, 490 °C, 500 °C, 510 °C, 520 °C, 530 °C, 540 °C, 550 °C, 560 °C, 570 °C, 580 °C, 590 °C, 600 °C, 610 °C, 620 °C, or 630 °C. In some embodiments, the heating rate to the peak metal temperature can be about 70 °C/hour or less, about 60 °C/hour or less, or about 50 °C/hour or less.

[0099] Following the pre-heating step, a hot rolling step can be performed. Prior to the start of hot rolling, the pre-heated product can be allowed to cool down to room temperature or to a desired temperature, such as from about 200 °C to about 425 °C. For example, the preheated product can be allowed to cool to a temperature of from about 200 °C to about 400 °C, about 250 °C to about 375 °C, about 300 °C to about 425 °C, or from about 350 °C to about 400 °C. The pre-heated product can then be hot rolled at a hot rolling start temperature, for example, from about 200 °C to about 450 °C, to produce a hot rolled intermediate product (e.g., a hot rolled plate, a hot rolled shate, or a hot rolled sheet) having a gauge from about 3 mm to about 100 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, or anywhere in between). For example, the pre-heated product can be hot rolled to an intermediate gauge of 9.5 mm from an initial gauge of 65 mm.

[0100] During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is less than about 400° C. For example, the temperature of the hot rolled intermediate product upon exit from the hot rolling mill can be less than about 390 °C (e.g., less than about 380 °C, less than about 370 °C, less than about 360 °C, less than about 350 °C, less than about 340 °C, less than about 330 °C, less than about 325 °C, less than about 320 °C, less than about 310 °C, less than about 300 °C, less than about 290 °C, less than about 280 °C, less than about 270 °C, less than about 260 °C, or less than about 250 °C). The exit temperature of the hot rolled intermediate product from the hot rolling step can control the microstructure of the aluminum alloy. In particular, aluminum alloys produced from a high content of recycled material require critically controlled heating rates, temperatures, and other operating parameters during the hot rolling step to produce an aluminum alloy product with the mechanical properties recited herein.

[0101] Individual layers can be joined as described herein to form a cladded aluminum alloy product by any means known to persons of ordinary skill in the art. For example, two layers can be joined by direct chill co-casting as described in, for example, U.S. Pat. Nos. 7,748,434 and 8,927,113, both of which are hereby incorporated by reference in their entireties; fusion casting by hot and cold rolling a composite cast ingot as described in U.S. Pat. No. 7,472,740, which can be also referred to by the trade name FUSION™ (Novelis) and is hereby incorporated by reference in its entirety; or by roll bonding to achieve the required metallurgical bonding between adjacent layers; or by other methods as known to persons of ordinary skill in the art. The initial dimensions and final dimensions of the clad aluminum alloy products described herein can be determined by the desired properties of the overall final product. One skilled in the art will recognize that similar methods can be employed when there is one or more intervening layers between the wrought cladding layer and the core layer and/or between the core layer and the sacrificial anode layer.

[0102] The roll bonding process can be carried out in different manners, as known to those of ordinary skill in the art. For example, the roll-bonding process can include both hot rolling and cold rolling. Further, the roll bonding process can be a one-step process or a multi-step process in which the material is gauged down during successive rolling steps. Separate rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, solvent cleaning steps, etching steps, heating steps, cooling steps, and the like.

[0103] The cladded plate, shate, coil, or sheet can then be cold rolled using conventional cold rolling mills and technology. The cold rolled clad sheet can have a gauge of from about 0.03 mm to about 10 mm (e.g., from 0.7 mm to 6.5 mm). Optionally, the cold rolled clad sheet can have a gauge of 0.03 mm, 0.05 mm, 0.1 mm, 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, or 10.0 mm.

[0104] The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to about 95 % (e.g., up to about 10%, up to about 20%, up to about 30%, up to about 40%, up to about 50%, up to about 60%, up to about 70%, up to about 80%, up to 85%, up to 90% or up to about 95% reduction). Optionally, an interannealing step can be performed during the cold rolling step. The interannealing step can be performed at a temperature of from about 200° C to about 450 °C (e.g., 200° C, 210 °C, 220 °C, 230 °C, 240 °C, 250 °C, 260 °C, 270 °C, 280 °C, 290 °C, 300 °C, 310 °C, 320 °C, 330 °C, 340 °C, 350 °C, 360 °C, 370 °C, 380 °C, 390 °C, 400 °C, 410 °C, 420 °C, 430 °C, 440 °C, or 450 °C). In some cases, the interannealing step comprises multiple processes. In some non-limiting examples, the interannealing step includes heating the cladded plate, shate, coil, or sheet to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, the cladded plate, shate, coil, or sheet can be heated to about 410 °C for about 1 hour and then heated to about 330 °C for about 2 hours.

Uses and Applications

[0105] Uses and applications of the cladded aluminum alloy products described herein are included within the scope of the present invention, as are products, forms, apparatuses, and similar things fabricated with or comprising the aluminum alloys described herein. The processes for fabricating, producing, or manufacturing such products, forms, apparatuses, and similar things are also included within the scope of the present invention.

[0106] Brazing, as incorporated into the embodiments of the present invention, includes, but is not limited to, vacuum brazing, controlled atmosphere brazing (CAB), Ni plating processes, flame brazing, induction brazing, laser brazing, open atmosphere brazing or molten salt brazing.

[0107] To be suitable for CAB brazing, the aluminum alloys described herein contained in a layer forming a joint via brazing (e.g., the wrought cladding layer and, optionally, the sacrificial anode layer) should contain less than or equal to 0.3 wt. % Mg, unless special fluxes are used to limit or eliminate the formation of the KMgF2 needles. To be suitable for vacuum brazing, the aluminum alloy should contain from approximately 0.2 wt. % to 2 wt. % Mg. For example, the aluminum alloy may contain up to approximately 0.5 wt. % Mg. Mg content in the aluminum alloy may be unspecified in some embodiments of the present invention, although it may still be present in the aluminum alloy.

[0108] CAB refers to a batch, semi-continuous, or continuous brazing process which utilizes an inert atmosphere, for example, nitrogen, argon or helium in the brazing of alloy articles. In CAB, the brazing atmosphere in the furnace during the brazing operation is at about regular atmospheric pressure, although a slight under-pressure (for example working at a pressure of 0.1 bar or more) or having a slight over-pressure can be used to facilitate the control of the inert atmosphere and to prevent an influx of oxygen containing gas into the brazing furnace.

[0109] Vacuum brazing can be carried out at relatively low atmosphere pressure in the order of about 1 x 10'⁴ mbar or less (e.g., 1 x 10'⁵ mbar or less or 1 x 10'⁶ mbar or less).

[0110] One exemplary product is a heat exchanger. Heat exchangers are produced by the assembly of parts comprising tubes, plates, fins, headers, and side supports to name a few. For example, a radiator is assembled from tubes, fins, headers, and side supports. Parts of the heat exchanger can be clad with a wrought cladding layer on one or two sides. Once assembled, a heat exchanger unit is secured by banding or such device to hold the unit together through fluxing and brazing. Brazing is commonly affected by passing the unit through a tunnel furnace. Brazing can also be performed by dipping in molten salt or in a batch or semi-batch process. The unit is heated to a brazing temperature between about 570 °C and about 620 °C, soaked at an appropriate temperature until joints are created by capillary forces and then cooled below the solidus temperature of the aluminum alloy of the wrought cladding layer and/or the sacrificial anode layer. Heating rate is dependent on the furnace type and the size of the heat exchanger produced.

[oni] Some other exemplary products that can be made with the alloys of the present invention are described and shown in U.S. Pat. No. 8,349,470. Some examples of such products are an evaporator plate, an evaporator, a radiator, a heater, a heater core, a condenser, condenser tubes, various tubes and pipes, a manifold, and some structural features, such as side supports.

[0112] Advantageously, the chemistry of the aluminum alloys described herein for the wrought cladding layer and the sacrificial anode layer may improve the corrosion resistance of the cladded aluminum alloy product. This may be particularly advantageous at mitigating a corrosion pathway from the outside to the inside of heat exchangers with stacked plate or shell designs which are often used for oil coolers, charge air coolers, and chillers.

ILLUSTRATIVE ASPECTS

[0113] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4 ”).

[0114] Aspect 1. A process for producing a cladded aluminum alloy product comprising a core layer, a wrought cladding layer, and a sacrificial anode layer, the process comprising: joining the core layer, the wrought cladding layer, and the sacrificial anode layer such that the core layer is between the wrought cladding layer and the sacrificial anode layer; and wherein the wrought cladding layer comprises an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum.

[0115] Aspect 2. The process of aspect 1, wherein the cladded aluminum alloy product further comprises an interlayer between the core layer and the wrought cladding layer; wherein the joining step includes (i) assembling the interlayer onto a first surface of the core layer, assembling the wrought cladding layer onto the interlayer, and assembling the sacrificial anode layer onto a second surface of the core layer, wherein the first surface and the second surface of the core layer are on opposing sides of the core layer, and (ii) hot roll bonding the assembled layers.

[0116] Aspect 3. The process of aspect 1, wherein the joining step includes (i) assembling the wrought cladding layer onto a first surface of the core layer, and assembling the sacrificial anode layer onto a second surface of the core layer, wherein the first surface and the second surface of the core layer are on opposing sides of the core layer, and (ii) hot roll bonding the assembled layers.

[0117] Aspect 4. The process of any previous or subsequent aspect, further comprising: casting the aluminum alloy; and rolling the cast aluminum alloy to a required thickness, thus producing the wrought cladding layer.

[0118] Aspect 5. The process of any previous or subsequent aspect, wherein the core layer is a wrought core layer, and wherein the sacrificial anode layer is a wrought sacrificial anode layer.

[0119] Aspect 6. The process of any previous or subsequent aspect, wherein the core layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.3 wt. % silicon, up to 1 wt. % iron, 0.05 wt. % to 1.2 wt. % copper, 0.6 wt. % to 2 wt. % manganese, up to 0.5 wt. % magnesium, up to 0.3 wt. % chromium, up to 0.5 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum.

[0120] Aspect 7. The process of any previous or subsequent aspect, wherein the sacrificial anode layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.5 wt. % silicon, 0.05 wt. % to 2 wt. % iron, up to 0.3 wt. % copper, up to 1.8 wt. % manganese, up to 3 wt. % magnesium, up to 0.3 wt. % chromium, up to 6 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum.

[0121] Aspect 8. A product fabricated by a process comprising the process of any previous or subsequent aspect.

[0122] Aspect 9. The product of aspect 8, wherein the product is a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and/or a manifold or assembly thereof.

[0123] Aspect 10. A process of joining two or more aluminum forms by brazing, the process comprising: assembling and securing the two or more aluminum forms together, wherein at least one of the two or more aluminum forms is a cladded aluminum alloy product comprising a core layer, a wrought cladding layer, and a sacrificial anode layer with the core layer between the wrought cladding layer and the sacrificial anode layer; and wherein the wrought cladding layer comprises an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum; heating the two or more aluminum forms, including the wrought cladding layer, to a brazing temperature until joints are created among the two or more aluminum forms by capillary forces; and cooling the two or more aluminum forms below solidus temperature of the wrought cladding layer.

[0124] Aspect 11. The process of aspect 10, wherein the brazing temperature is from 570 °C to 620 °C.

[0125] Aspect 12. The process of aspect 11, wherein the brazing is a controlled atmosphere brazing, and wherein the aluminum alloy of the wrought cladding layer comprises up to 0.3 wt. % magnesium.

[0126] Aspect 13. The process of aspect 11, wherein the brazing is a vacuum brazing, and wherein the aluminum alloy of the wrought cladding layer comprises from 0.2 wt. % to 1.5 wt. % magnesium.

[0127] Aspect 14. A cladded aluminum alloy product comprising: a core layer; a wrought cladding layer comprising an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum; and a sacrificial anode layer; and wherein the core layer is between the wrought cladding layer and the sacrificial anode layer.

[0128] Aspect 15. The cladded aluminum alloy product of aspect 14, further comprising an interlayer between the core layer and the wrought cladding layer.

[0129] Aspect 16. The cladded aluminum alloy product of aspect 14, wherein the wrought cladding layer is brazed directly to the core layer.

[0130] Aspect 17. The cladded aluminum alloy product of any of aspects 14-16, wherein the sacrificial anode layer is brazed directly to the core layer. [0131] Aspect 18. A product fabricated with the cladded aluminum alloy product of any of aspects 14-17.

[0132] Aspect 19. The product of aspect 18, wherein the product is a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and/or a manifold or assembly thereof.

[0133] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

WHAT IS CLAIMED IS:

1. A process for producing a cladded aluminum alloy product comprising a core layer, a wrought cladding layer, and a sacrificial anode layer, the process comprising: joining the core layer, the wrought cladding layer, and the sacrificial anode layer such that the core layer is between the wrought cladding layer and the sacrificial anode layer; and wherein the wrought cladding layer comprises an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum.

2. The process of claim 1, wherein the cladded aluminum alloy product further comprises an interlayer between the core layer and the wrought cladding layer; and wherein the joining step includes (i) assembling the interlayer onto a first surface of the core layer, assembling the wrought cladding layer onto the interlayer, and assembling the sacrificial anode layer onto a second surface of the core layer, wherein the first surface and the second surface of the core layer are on opposing sides of the core layer, and (ii) hot roll bonding the assembled layers.

3. The process of claim 1, wherein the joining step includes (i) assembling the wrought cladding layer onto a first surface of the core layer, and assembling the sacrificial anode layer onto a second surface of the core layer, wherein the first surface and the second surface of the core layer are on opposing sides of the core layer, and (ii) hot roll bonding the assembled layers.

4. The process of any preceding claim, further comprising: casting the aluminum alloy; and rolling the cast aluminum alloy to a required thickness, thus producing the wrought cladding layer.

5. The process of any preceding claim, wherein the core layer is a wrought core layer, and wherein the sacrificial anode layer is a wrought sacrificial anode layer.

6. The process of any preceding claim, wherein the core layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.3 wt. % silicon, up to 1 wt. % iron, 0.05 wt. % to 1.2 wt. % copper, 0.6 wt. % to 2 wt. % manganese, up to 0.5 wt. % magnesium, up to 0.3 wt. % chromium, up to 0.5 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum.

7. The process of any preceding claim, wherein the sacrificial anode layer comprises an aluminum alloy that comprises 0.05 wt. % to 1.5 wt. % silicon, 0.05 wt. % to 2 wt. % iron, up to 0.3 wt. % copper, up to 1.8 wt. % manganese, up to 3 wt. % magnesium, up to 0.3 wt. % chromium, up to 6 wt. % zinc, up to 0.3 wt. % titanium, up to 0.3 wt. % zirconium, up to 0.3 wt. % vanadium, up to 0.15 wt. % of impurities, and aluminum.

8. A product fabricated by a process comprising the process of any preceding claim.

9. The product of claim 8, wherein the product is a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and/or a manifold or assembly thereof.

10. A process of joining two or more aluminum forms by brazing, the process comprising: assembling and securing the two or more aluminum forms together, wherein at least one of the two or more aluminum forms is a cladded aluminum alloy product comprising a core layer, a wrought cladding layer, and a sacrificial anode layer with the core layer between the wrought cladding layer and the sacrificial anode layer; and wherein the wrought cladding layer comprises an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum; heating the two or more aluminum forms, including the wrought cladding layer, to a brazing temperature until joints are created among the two or more aluminum forms by capillary forces; and cooling the two or more aluminum forms below solidus temperature of the wrought cladding layer.

11. The process of claim 10, wherein the brazing temperature is from 570 °C to 620 °C.

12. The process of claim 11, wherein the brazing is a controlled atmosphere brazing, and wherein the aluminum alloy of the wrought cladding layer comprises up to 0.3 wt. % magnesium.

13. The process of claim 11, wherein the brazing is a vacuum brazing, and wherein the aluminum alloy of the wrought cladding layer comprises from 0.2 wt. % to 1.5 wt. % magnesium.

14. A cladded aluminum alloy product comprising: a core layer; a wrought cladding layer comprising an aluminum alloy that comprises 6 wt. % to 13 wt. % silicon, 0.1 wt. % to 0.7 wt. % iron, 0.1 wt. % to 1.5 wt. % copper, 0.1 wt. % to 1.9 wt. % manganese, up to 2 wt. % magnesium, up to 0.1 wt. % chromium, up to 3 wt. % zinc, up to 0.2 wt. % titanium, up to 0.1 wt. % zirconium, up to 0.15 wt. % of impurities, and aluminum; and a sacrificial anode layer; and wherein the core layer is between the wrought cladding layer and the sacrificial anode layer.

15. The cladded aluminum alloy product of claim 14, further comprising an interlayer between the core layer and the wrought cladding layer.

16. The cladded aluminum alloy product of claim 14, wherein the wrought cladding layer is brazed directly to the core layer.

17. The cladded aluminum alloy product of any of claims 14-16, wherein the sacrificial anode layer is brazed directly to the core layer.

18. A product fabricated with the cladded aluminum alloy product of any of claims 14-17.

19. The product of claim 18, wherein the product is a chiller, heater, evaporator plate, evaporator, radiator, heater core, condenser, charge air cooler / intercooler, oil cooler, cold plate, base plate, tube or tubestock, pipe, finstock, stamped parts or bracketry, and/or a manifold or assembly thereof.