The present disclosure concerns embodiments of aluminum alloy compositions exhibiting superior microstructural stability and strength at high temperatures. The disclosed aluminum alloy compositions comprise particular combinations of components that contribute the ability of the alloys to exhibit improved microstructural stability and hot tearing resistance as compared to conventional alloys. Also disclosed herein are embodiments of methods of making and using the alloys.

The present disclosure concerns embodiments of aluminum alloy compositions exhibiting superior microstructural stability and strength at high temperatures. The disclosed aluminum alloy compositions comprise particular combinations of components that contribute the ability of the alloys to exhibit improved microstructural stability and hot tearing resistance as compared to conventional alloys. Also disclosed herein are embodiments of methods of making and using the alloys.

An aluminum alloy has a low thermal conductivity at room temperature (25° C.) and a high thermal conductivity at high temperature (200° C.). The aluminum alloy includes 1˜2 wt % of magnesium (Mg), 1˜2 wt % of copper (Cu), 1˜2 wt % of zinc (Zn), 0.5˜2 wt % of nickel (Ni), and the remainder of aluminum (Al) and inevitable impurities.

An aluminum alloy has a low thermal conductivity at room temperature (25° C.) and a high thermal conductivity at high temperature (200° C.). The aluminum alloy includes 1˜2 wt % of magnesium (Mg), 1˜2 wt % of copper (Cu), 1˜2 wt % of zinc (Zn), 0.5˜2 wt % of nickel (Ni), and the remainder of aluminum (Al) and inevitable impurities.

The present invention relates to aluminum alloy products that can be riveted and possess excellent ductility and toughness properties. The present invention also relates to a method of producing the aluminum alloy products. In particular, these products have application in the automotive industry.

The present invention relates to aluminum alloy products that can be riveted and possess excellent ductility and toughness properties. The present invention also relates to a method of producing the aluminum alloy products. In particular, these products have application in the automotive industry.

The present invention discloses a product comprising a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles. In another embodiment, the present invention discloses a 8111 or 8921 aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater than the average values of the same alloy in O-temper made from feedstock prepared by slab or roll casting processes. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles.

The present invention discloses a product comprising a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles. In another embodiment, the present invention discloses a 8111 or 8921 aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater than the average values of the same alloy in O-temper made from feedstock prepared by slab or roll casting processes. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles.

A method of manufacturing an AA2xxx-series aluminium alloy plate product having improved fatigue failure resistance and a reduced number of flaws, the method comprising the following steps (a) casting an ingot of an aluminium alloy of the 2xxx-series, the aluminium alloy comprising (in wt. %): Cu 1.9 to 7.0, Mg 0.3 to 1.8, Mn up to 1.2, balance aluminium and impurities, each 0.05 max., total 0.15; (b) homogenizing and/or preheating the cast ingot; (c) hot rolling the ingot into a plate product by rolling the ingot with multiple rolling passes characterized in that, when at an intermediate thickness of the plate between 100 and 200 mm, at least one high reduction hot rolling pass is carried out with a thickness reduction of at least 15%; wherein the plate product has a final thickness of less than 60 mm. The invention is also related to an aluminium alloy product produced by this method.

A method of manufacturing an AA2xxx-series aluminium alloy plate product having improved fatigue failure resistance and a reduced number of flaws, the method comprising the following steps (a) casting an ingot of an aluminium alloy of the 2xxx-series, the aluminium alloy comprising (in wt. %): Cu 1.9 to 7.0, Mg 0.3 to 1.8, Mn up to 1.2, balance aluminium and impurities, each 0.05 max., total 0.15; (b) homogenizing and/or preheating the cast ingot; (c) hot rolling the ingot into a plate product by rolling the ingot with multiple rolling passes characterized in that, when at an intermediate thickness of the plate between 100 and 200 mm, at least one high reduction hot rolling pass is carried out with a thickness reduction of at least 15%; wherein the plate product has a final thickness of less than 60 mm. The invention is also related to an aluminium alloy product produced by this method.